High velocity impact induced microstructure evolution during deposition of cold spray coatings: A review

Abstract Cold spray is a fast growing coating process involving in high strain rate deformation of spray particles. Early investigations stressed the retaining of feedstock microstructures into deposits. However, in recent years, metastable microstructures including high density of dislocations, nanosized grains and localized amorphous phase have been frequently observed through detailed microstructure characterization and it was found that those metastable microstructures remarkably affect the coating properties. In this review article, the evolution mechanisms of metastable microstructure in a cold spray coating during deposition of spray particles were examined in terms of in-situ densification, residual stress, dislocation multiplication, grain refining, phase transformation and amorphization through typical materials. Feedstock microstructure design, in-process control and material selection are essential approaches to acquire the coatings with desired microstructure.

[1]  Guanjun Yang,et al.  Simultaneous strengthening and toughening effects in WC–(nanoWC–Co) , 2012 .

[2]  K. Ogawa,et al.  Influence of crystallite size and lattice spacing on thermal conduction of polycrystalline copper deposited by solid particle impingement: Contribution of electron and phonon conduction , 2012 .

[3]  E. Lavernia,et al.  Cold gas dynamic spraying of iron-base amorphous alloy , 2006 .

[4]  J. Akedo.  Room Temperature Impact Consolidation (RTIC) of Fine Ceramic Powder by Aerosol Deposition Method and Applications to Microdevices , 2008 .

[5]  Chang-Jiu Li,et al.  Deposition characteristics of titanium coating in cold spraying , 2003 .

[6]  F. Casadei,et al.  Corrosion resistance of cold-sprayed Ta coatings in very aggressive conditions , 2010 .

[7]  S. Seal,et al.  Transmission electron microscopy of cold sprayed 1100 aluminum coating , 2005 .

[8]  Changhee Lee,et al.  Fabrication of WC–Co coatings by cold spray deposition , 2005 .

[9]  Wenya Li,et al.  Characterization of cold-sprayed nanostructured Fe-based alloy , 2010 .

[10]  B. Bonferroni,et al.  Depth-sensing indentation for assessing the mechanical properties of cold-sprayed Ta , 2010 .

[11]  D. G. McCartney,et al.  Computational modelling of titanium particles in warm spray , 2011 .

[12]  S. Joshi,et al.  Effect of Process Parameters and Heat Treatments on Properties of Cold Sprayed Copper Coatings , 2007 .

[13]  Keith Murray,et al.  High Pressure Cold Sprayed (HPCS) and Low Pressure Cold Sprayed (LPCS) Coatings Prepared from OFHC Cu Feedstock: Overview from Powder Characteristics to Coating Properties , 2012, Journal of Thermal Spray Technology.

[14]  V. Luzin,et al.  Through-Thickness Residual Stress Measurement in Metal and Ceramic Spray Coatings by Neutron Diffraction , 2008 .

[15]  Jie Zhao,et al.  Influence of annealing treatment on the microstructure and mechanical performance of cold sprayed 304 stainless steel coating , 2011 .

[16]  G. Sundararajan,et al.  Effect of heat treatment on properties of cold sprayed nanocrystalline copper alumina coatings , 2007 .

[17]  E. Arzt,et al.  Microstructural development in dispersion strengthened NiAl produced by mechanical alloying and secondary recrystallization , 1997 .

[18]  Xiao-Tao Luo,et al.  High strain rate induced localized amorphization in cubic BN/NiCrAl nanocomposite through high velocity impact , 2011 .

[19]  Chang-jiu Li,et al.  Preliminary Study of Performance of Dye-Sensitized Solar Cell of Nano-TiO2 Coating Deposited by Vacuum Cold Spraying , 2006 .

[20]  Michel Jeandin,et al.  The Influence of the Substrate on the Deposition of Cold-Sprayed Titanium: An Experimental and Numerical Study , 2011 .

[21]  C. Schuh,et al.  Electrodeposited Al―Mn alloys with microcrystalline, nanocrystalline, amorphous and nano-quasicrystalline structures , 2009 .

[22]  Mica Grujicic,et al.  Computational analysis of the interfacial bonding between feed-powder particles and the substrate in the cold-gas dynamic-spray process , 2003 .

[23]  Chang-jiu Li,et al.  Influence of substrate hardness transition on built-up of nanostructured WC-12Co by cold spraying , 2010 .

[24]  B. Kear,et al.  Nanopowder deposition by supersonic rectangular jet impingement , 2000 .

[25]  Changhee Lee,et al.  Dynamic amorphization and recrystallization of metals in kinetic spray process , 2008 .

[26]  Mingxing Zhang,et al.  Residual stress and thermo-mechanical properties of cold spray metal coatings , 2011 .

[27]  Wenya Li,et al.  Examination on the Calculation Method for Modeling the Multi-Particle Impact Process in Cold Spraying , 2010 .

[28]  Brian Derby,et al.  The dependence of grain size on stress during dynamic recrystallisation , 1991 .

[29]  F. Gärtner,et al.  Microstructural bonding features of cold sprayed face centered cubic metals , 2004 .

[30]  Changhee Lee,et al.  Influence of the interface temperature and strain gradients on the impact energy model of a soft particle on a hard substrate during kinetic spraying , 2011 .

[31]  G. K. Williamson,et al.  X-ray line broadening from filed aluminium and wolfram , 1953 .

[32]  P. Shipway,et al.  Effect of deposition conditions on the properties and annealing behavior of cold-sprayed copper , 2006 .

[33]  G. Sundararajan,et al.  The Influence of Powder Particle Velocity and Microstructure on the Properties of Cold Sprayed Copper Coatings , 2011 .

[34]  Stefan Riekehr,et al.  Mechanical properties of cold-sprayed and thermally sprayed copper coatings , 2006 .

[35]  M. Honkanen,et al.  Cold-sprayed copper and tantalum coatings — Detailed FESEM and TEM analysis , 2010 .

[36]  Lu,et al.  Superplastic extensibility of nanocrystalline copper at room temperature , 2000, Science.

[37]  H. Koivuluoto,et al.  Microstructural Studies of Cold Sprayed Copper, Nickel, and Nickel-30% Copper Coatings , 2007 .

[38]  G. Kim,et al.  Mechanical Characteristics of Al-Co-Ce Coatings Produced by the Cold Spray Process , 2007, International Thermal Spray Conference.

[39]  J. Schoenung,et al.  Synthesis and mechanical properties of nanocrystalline Ni coatings produced by cold gas dynamic spraying , 2006 .

[40]  F. Gärtner,et al.  Formation of persistent dislocation loops by ultra-high strain-rate deformation during cold spraying , 2005 .

[41]  H. Jahed,et al.  Microstructure and fatigue behavior of cold spray coated Al5052 , 2012 .

[42]  Wenya Li,et al.  Effect of substrate hardness on the deformation behavior of subsequently incident particles in cold spraying , 2011 .

[43]  R. Birringer,et al.  Diffusion of silver in nanocrystalline copper between 303 and 373 K , 1989 .

[44]  Mingxing Zhang,et al.  Optimisation of stainless steel cold spray coatings using mixed particle size distributions , 2011 .

[45]  J. Lu,et al.  Nitriding Iron at Lower Temperatures , 2003, Science.

[46]  B. Jodoin,et al.  CoNiCrAlY microstructural changes induced during Cold Gas Dynamic Spraying , 2008 .

[47]  N. Birbilis,et al.  Interfacial structure between particles in an aluminum deposit produced by cold spray , 2011 .

[48]  L. Ajdelsztajn,et al.  WC-based composite coatings prepared by the pulsed gas dynamic spraying process: Effect of the feedstock powders , 2008 .

[49]  W. Goddard,et al.  Strain Rate Induced Amorphization in Metallic Nanowires , 1999 .

[50]  K. Ko,et al.  Effect of gas pressure on Al coatings by cold gas dynamic spray , 2008 .

[51]  B. Jodoin,et al.  Cold-Spray processing of a nanocrystalline Al−Cu−Mg−Fe−Ni alloy with Sc , 2006 .

[52]  M. Tiryakioğlu,et al.  On the characterization of bulk copper produced by cold gas dynamic spray processing in as fabricated and annealed conditions , 2011 .

[53]  Chang-jiu Li,et al.  Characterization of Nanostructured WC-Co Deposited by Cold Spraying , 2007, International Thermal Spray Conference.

[54]  Wenya Li,et al.  Effect of impact-induced melting on interface microstructure and bonding of cold-sprayed zinc coating , 2010 .

[55]  P. Shipway,et al.  Effect of cold spray deposition of a titanium coating on fatigue behavior of a titanium alloy , 2006 .

[56]  F. C. Lovey,et al.  Shape memory in Cu-based alloys: phenomenological behavior at the mesoscale level and interaction of martensitic transformation with structural defects in Cu-Zn-Al , 1999 .

[57]  Paulo S. Branicio,et al.  Large deformation and amorphization of Ni nanowires under uniaxial strain: A molecular dynamics study , 2000 .

[58]  L. Ajdelsztajn,et al.  Properties of SiC-reinforced aluminum alloy coatings produced by the cold gas dynamic spraying process , 2008 .

[59]  Christian Coddet,et al.  Microstructure, microhardness and dry friction behavior of cold-sprayed tin bronze coatings , 2007 .

[60]  H. Liao,et al.  On high velocity impact of micro-sized metallic particles in cold spraying , 2006 .

[61]  Wenya Li,et al.  Numerical Investigation on Effects of Interactions Between Particles on Coating Formation in Cold Spraying , 2009 .

[62]  J. Jonas,et al.  Dynamic and post-dynamic recrystallization under hot, cold and severe plastic deformation conditions , 2014 .

[63]  S. Kuroda,et al.  Thermal softening effect on the deposition efficiency and microstructure of warm sprayed metallic powder , 2009 .

[64]  T. Okabe,et al.  Computer simulation of cold sprayed deposition using smoothed particle hydrodynamics , 2011 .

[65]  S. Bagherifard,et al.  Experimental and numerical study of residual stress evolution in cold spray coating , 2014 .

[66]  J. Schoenung,et al.  Cold spray deposition of nanocrystalline aluminum alloys , 2005 .

[67]  R. Chromik,et al.  Characterization of Ti cold spray coatings by indentation methods , 2011 .

[68]  Chang-Jiu Li,et al.  Characterization of microstructure of Nano-TiO2 coating deposited by vacuum cold spraying , 2006, Journal of Thermal Spray Technology.

[69]  M. Meyers,et al.  Microstructural evolution in adiabatic shear localization in stainless steel , 2002 .

[70]  Wenya Li,et al.  Deposition behavior of thermally softened copper particles in cold spraying , 2013 .

[71]  J. Cahn.  The thermochemical implications of deformation twinning and martensite transformations , 1992 .

[72]  Chang-jiu Li,et al.  Microstructure Features of Cold-Sprayed NiCoCrAlTaY Coating and its High Temperature Oxidation Behavior , 2011 .

[73]  J. Legoux,et al.  Mechanical behavior of Ti cold spray coatings determined by a multi-scale indentation method , 2011 .

[74]  Wenya Li,et al.  Deformation behavior of the oxide film on the surface of cold sprayed powder particle , 2012 .

[75]  Jun Akedo,et al.  Jet molding system for realization of three-dimensional micro-structures , 1998 .

[76]  H. Liao,et al.  Effect of annealing treatment on the microstructure and properties of cold-sprayed Cu coating , 2006 .

[77]  Chang-jiu Li,et al.  Study of oxidation behavior of nanostructured NiCrAlY bond coatings deposited by cold spraying , 2008 .

[78]  S. Yue,et al.  Microstructure and nanohardness of cold-sprayed coatings: Electron backscattered diffraction and nanoindentation studies , 2010 .

[79]  C. Berndt,et al.  Deposition effects of WC particle size on cold sprayed WC-Co coatings , 2011 .

[80]  Sanjay Sampath,et al.  Integrated characterization of cold sprayed aluminum coatings , 2007 .

[81]  Changhee Lee,et al.  The influence of process parameters on deposition characteristics of a soft/hard composite coating in kinetic spray process , 2008 .

[82]  Guanjun Yang,et al.  Cold spraying of Fe/Al powder mixture: Coating characteristics and influence of heat treatment on the phase structure , 2008 .

[83]  Chang-jiu Li,et al.  Thermal fatigue behavior of thermal barrier coatings with the MCrAlY bond coats by cold spraying and low-pressure plasma spraying , 2010 .

[84]  Changhee Lee,et al.  Formation of coating and tribological behavior of kinetic sprayed Fe-based bulk metallic glass , 2011 .

[85]  X. Xiong,et al.  Dependence of Bonding Mechanisms of Cold Sprayed Coatings on Strain-Rate-Induced Non-Equilibrium Phase Transformation , 2011 .

[86]  Tobias Schmidt,et al.  Development of a generalized parameter window for cold spray deposition , 2006 .

[87]  Changhee Lee,et al.  Interfacial bonding and microstructural evolution of Al in kinetic spraying , 2012, Journal of Materials Science.

[88]  S. Scudino,et al.  Cold sprayed aluminum based glassy coating: Synthesis, wear and corrosion properties , 2013 .

[89]  Han Huang,et al.  Microstructure characterization and nanomechanics of cold-sprayed pure Al and Al-Al2O3 composite coatings , 2013 .

[90]  T. Laha,et al.  Effect of carrier gases on microstructural and electrochemical behavior of cold-sprayed 1100 aluminum coating , 2005 .

[91]  Changhee Lee,et al.  Nanostructure formation and its effects on the mechanical properties of kinetic sprayed titanium coating , 2010 .

[92]  H. Liao,et al.  Ball milled Ni–Ti powder deposited by cold spraying , 2009 .

[93]  N. Birbilis,et al.  High resolution microstructure characterization of the interface between cold sprayed Al coating and Mg alloy substrate , 2014 .

[94]  Guanjun Yang,et al.  Influence of Substrate Hardness on Deposition Behavior of Single Porous WC-12Co Particles in Cold Spraying , 2008, International Thermal Spray Conference.

[95]  M. Yu,et al.  Effect of Vacuum Heat Treatment on Tensile Strength and Fracture Performance of Cold-Sprayed Cu-4Cr-2Nb Coatings , 2011, International Thermal Spray Conference.

[96]  K. Lu.  Nanocrystalline metals crystallized from amorphous solids: nanocrystallization, structure, and properties , 1996 .

[97]  C. Berndt,et al.  Microstructural characteristics of cold-sprayed nanostructured WC-Co coatings , 2002 .

[98]  Jae-il Jang,et al.  Correlation of particle impact conditions with bonding, nanocrystal formation and mechanical properties in kinetic sprayed nickel , 2012 .

[99]  Xiao-Tao Luo,et al.  Thermal Stability of Microstructure and Hardness of Cold-Sprayed cBN/NiCrAl Nanocomposite Coating , 2011, Journal of Thermal Spray Technology.

[100]  Patrick Wollants,et al.  Thermally- and stress-induced thermoelastic martensitic transformations in the reference frame of equilibrium thermodynamics , 1993 .

[101]  N. Millot,et al.  Deposition and characterization of cold sprayed nanocrystalline NiTi , 2011 .

[102]  A. Gerlich,et al.  Interfacial heating during low-pressure cold-gas dynamic spraying of aluminum coatings , 2011, Journal of Materials Science.

[103]  Tobias Schmidt,et al.  The cold spray process and its potential for industrial applications , 2005, Thermal Spray 2005: Proceedings from the International Thermal Spray Conference.

[104]  Jie Zhao,et al.  Influence of Gas Temperature on Microstructure and Properties of Cold Spray 304SS Coating , 2011 .

[105]  H. Prask,et al.  Residual stress in sprayed Ni+5%Al coatings determined by neutron diffraction , 2002 .

[106]  S. Kuroda,et al.  Grain refinement in a single titanium powder particle impacted at high velocity , 2008 .

[107]  Charles K. S. Moy,et al.  Investigating the microstructure and composition of cold gas-dynamic spray (CGDS) Ti powder deposited on Al 6063 substrate , 2010 .

[108]  Chao Sun,et al.  Microstructure and corrosion performance of a cold sprayed aluminium coating on AZ91D magnesium alloy , 2010 .

[109]  A. Jyothirmayi,et al.  The influence of heat treatment on the microstructural, mechanical and corrosion behaviour of cold sprayed SS 316L coatings , 2009 .

[110]  G. Sundararajan,et al.  The influence of process parameters and heat treatment on the properties of cold sprayed silver coatings , 2011 .

[111]  Changhee Lee,et al.  Effect of particle size on the microstructure and properties of kinetic sprayed nickel coatings , 2010 .

[112]  Chang-jiu Li,et al.  Formation of metastable phases in cold-sprayed soft metallic deposit , 2005 .

[113]  J. M. Guilemany,et al.  Residual stress development in cold sprayed Al, Cu and Ti coatings , 2013 .

[114]  J. Legoux,et al.  Dynamic recrystallization in the particle/particle interfacial region of cold-sprayed nickel coating: Electron backscatter diffraction characterization , 2009 .

[115]  Hamid Assadi,et al.  Bonding mechanism in cold gas spraying , 2003 .

[116]  Xiao-Tao Luo,et al.  Multiple strengthening mechanisms of cold-sprayed cBNp/NiCrAl composite coating , 2011 .

[117]  A. Korsunsky,et al.  The character of dislocation structure evolution in nanocrystalline FCC Ni-Co alloys prepared by high-energy mechanical milling , 1999 .

[118]  M. Jahedi,et al.  Microstructural Refinement within a Cold-Sprayed Copper Particle , 2009 .

[119]  F. J. Humphreys,et al.  Recrystallization and Related Annealing Phenomena , 1995 .