Cold spraying and laser cladding as an alternative to electroplating processes

2019 ◽  
Vol 91 (2) ◽  
pp. 205-215 ◽  
Author(s):  
Jaroslaw Sienicki ◽  
Wojciech Zórawski ◽  
Adam Dworak ◽  
Piotr Koruba ◽  
Piotr Jurewicz ◽  
...  
Keyword(s):  
Cold Spray ◽  
Laser Cladding ◽  
Process Parameters ◽  
Process Development ◽  
Research Work ◽  
Cold Spraying ◽  
High Energy ◽  
Titanium Coating ◽  
Low Carbon ◽  
Content Type

Purpose The purpose of this paper is to propose cold spraying and laser cladding processes as alternatives to cadmium and chromium electroplating, respectively. There are many substances or chemicals within the coating technology that can be identified as substances of very high concern because of their carcinogenic or mutagenic nature. Cadmium and chromium undoubtedly belong to these items and are the basic constituents of electrolytic coating processes. Finding an alternative and adapting to the existing restrictions of the usage of such hazardous products stands for many to be or not to be in the market. Design/methodology/approach The research work was focused on down selecting the appropriate materials, producing the coating samples, testing their properties and optimizing process parameters by statistical method. On the one hand, the high-pressure cold spray system and spraying of the titanium coating on the landing gear component, and on the other hand, the high-energy laser cladding facility and the wear resistant cobalt-based coating deposited onto the shock absorber piston. Substrates of these two applications were made of the same material, 4330 – high-strength low-carbon steel. Findings Meeting the requirements of Registration, Evaluation, Authorization and Restriction of Chemicals implies undertaking research and implementation work to identify alternative processes. The work provides the technical characteristics of new coatings justifying application readiness of the researched processes. Originality/value Taguchi’s design of experiment method was combined with the measurements and analysis of specified coating properties for the optimization of the cold spray process parameters. There is also laser cladding process development presented as a fast rate technology generating coatings with the unique properties.

Cold spray micro-defects and post-treatment technologies: a review

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Wang Zhizhong ◽  
Han Chao ◽  
Guosheng Huang ◽  
Han Bin ◽  
Han Bin
Keyword(s):  
Cold Spray ◽  
Influence Factors ◽  
Cold Spraying ◽  
Post Treatment ◽  
Treatment Technology ◽  
Treatment Methods ◽  
Content Type ◽  
Treatment Technologies ◽  
Single Method ◽  
Improved Performance

Purpose The deposition of particles onto a substrate during the cold spraying (CS) process relies on severe plastic deformation, so there are various micro-defects induced by insufficient deformation and severe crushing. To solve the problems, many post-treat techniques have been used to improving the quality by eliminating the micro-defects. This paper aims to help scholars and engineers in this field a better and systematic understand of CS technology by summarizing the post-treatment technologies that have been investigated recently years. Design/methodology/approach This review summarizes the types of micro-defects and introduces the effect of micro-defects on the properties of CS coating/additive manufactured, illustrates the post-treatment technologies and its effect on the microstructure and performances, and finally outlooks the future development trends of post-treatments for CS. Findings There are significant discoveries in post-treatment technology to change the performance of cold spray deposits. There are also many limitations for post-treatment methods, including improved performance and limitations of use. Thus, there is still a strong requirement for further improvement. Hybrid post-treatment may be a more ideal method, as it can eliminate more defects than a single method. The proposed ultrasonic impact treatment could be an alternative method, as it can densify and flatten the CS deposits. Originality/value It is the first time to reveal the influence factors on the performances of CS deposits from the perspective of microdefects, and proposed corresponding well targeted post-treatment methods, which is more instructive for improving the performances of CS deposits.

Fabrication and characterization of friction stir processed Al 6061 reinforced with TiB2-Al2O3

2020 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Ch. Mohana Rao ◽  
K. Mallikarjuna Rao
Keyword(s):  
Mechanical Properties ◽  
Aluminum Alloy ◽  
Process Parameters ◽  
Friction Stir Processing ◽  
Practical Implication ◽  
Research Work ◽  
Influence Of Process Parameters ◽  
Volume Percentage ◽  
Content Type ◽  
Friction Stir

PurposeThe objective of the paper is to evaluate the fabrication process and to study the influence of process parameters of friction stir processing of 6061-TiB2-Al2O3 Aluminum alloy surface composite on microhardness tensile strength, and microstructure.Design/methodology/approachFriction stir processing method is used for attaining the desired mechanical properties, and selectively processed reinforcements to fabricate the samples. The Taguchi technique was used to optimize rotational speed, travel speed and volume percentage of reinforcement particles to enhance the mechanical properties of 6061-TiB2-Al2O3 Aluminum alloy composite.FindingsThe fabrication of surface composites through FSP allows new inventions in terms of material with enhanced surface layers without changing the base metal.Practical implicationsTo examine the behavior of the surface of the composites in the different zones, the practical implication consists of the use of different characterization techniques like optical microscopy and scanning microscopy for microstructural behavior and the measurement of hardness and tensile tests for mechanical behavior.Originality/valueThe research work consists of tool design and process parameters, which can affect the final product (microstructural changes), and the performance of the modified surface layer behavior was studied and presented.

Surface Modification and Repair for Aircraft Life Enhancement and Structural Restoration

2010 ◽  
Vol 654-656 ◽  
pp. 763-766 ◽  
Author(s):  
Qian Chu Liu ◽  
Pud Baburamani ◽  
Wyman Zhuang ◽  
Darrem Gerrard ◽  
Bruce Hinton ◽  
...  
Keyword(s):  
Surface Modification ◽  
Cold Spray ◽  
Laser Cladding ◽  
Particle Deposition ◽  
Research Work ◽  
Spray Coating ◽  
Rolling Friction ◽  
Scientific Management ◽  
Friction Stir ◽  
Advantages And Disadvantages

Maintenance of ageing military aircraft structures encompasses both engineering and scientific management. In support of this, surface modification and repair methods are used on an opportunity basis to extend the life of aircraft in terms of fatigue and safety. Often, certain surface modification technologies have proved to be both cost effective and amenable for safe application. Some candidate technologies include shot peening, cold spray, deep surface rolling, friction stir welding, laser shock peening, and laser cladding. Whilst some technologies have been successfully applied to Australian Defence Force (ADF) aircraft in the past, some newer technologies are also being considered. The supersonic particle deposition (SPD) technology also known as cold spray coating has been recently approved for application on a helicopter gear box. Another technology of significance to ADF application is Laser Cladding (LC) technology. This paper briefly summarises the research work on these technologies at DSTO and discusses potential applications for aircraft components in the near future. It also provides an analysis of technologies and their potential advantages and disadvantages.

scholarly journals Cold-Sprayed Al6061 Coatings: Online Spray Monitoring and Influence of Process Parameters on Coating Properties

Coatings ◽  
2020 ◽  
Vol 10 (4) ◽  
pp. 348 ◽  
Author(s):  
Heli Koivuluoto ◽  
Jussi Larjo ◽  
Danilo Marini ◽  
Giovanni Pulci ◽  
Francesco Marra
Keyword(s):  
Cold Spray ◽  
Process Parameters ◽  
Cold Spraying ◽  
Deposition Efficiency ◽  
Particle Deformation ◽  
Influence Of Process Parameters ◽  
High Particle ◽  
High Kinetic Energy ◽  
Spray Processing ◽  
Particle Velocities

Process optimization and quality control are important issues in cold spraying and coating development. Because the cold spray processing is based on high kinetic energy by high particle velocities, online spray monitoring of particle inflight properties can be used as an assisting process tool. Particle velocities, their positions in the spray jet, and particle size measurements give valuable information about spraying conditions. This, in turn, improves reproducibility and reliability of coating production. This study focuses on cold spraying of Al6061 material and the connections between particle inflight properties and coating characteristics such as structures and mechanical properties. Furthermore, novel 2D velocity scan maps done with the HW CS2 online spray monitoring system are presented as an advantageous powder and spray condition controlling tool. Cold spray processing conditions were similar using different process parameters, confirmed with the online spray monitoring prior to coating production. Higher particle velocities led to higher particle deformation and thus, higher coating quality, denser structures, and improved adhesions. Also, deposition efficiency increased significantly by using higher particle velocities.

Development of predictive models for effective process parameter selection for single and overlapping laser clad bead geometry

2018 ◽  
Vol 24 (1) ◽  
pp. 214-228 ◽  
Author(s):  
Kush Aggarwal ◽  
R.J. Urbanic ◽  
Syed Mohammad Saqib
Keyword(s):  
Data Collection ◽  
Predictive Model ◽  
Laser Cladding ◽  
Process Planning ◽  
Process Parameters ◽  
Predictive Models ◽  
Goodness Of Fit ◽  
Bead Geometry ◽  
Content Type ◽  
Non Linear

Purpose The purpose of this work is to explore predictive model approaches for selecting laser cladding process settings for a desired bead geometry/overlap strategy. Complementing the modelling challenges is the development of a framework and methodologies to minimize data collection while maximizing the goodness of fit for the predictive models. This is essential for developing a foundation for metallic additive manufacturing process planning solutions. Design/methodology/approach Using the coaxial powder flow laser cladding method, 420 steel cladding powder is deposited on low carbon structural steel plates. A design of experiments (DOE) approach is taken using the response surface methodology (RSM) to establish the experimental configuration. The five process parameters such as laser power, travel speed, etc. are varied to explore their impact on the bead geometry. A total of three replicate experiments are performed and the collected data are assessed using a variety of methods to determine the process trends and the best modelling approaches. Findings There exist unpredictable, non-linear relationships between the process parameters and the bead geometry. The best fit for a predictive model is achieved with the artificial neural network (ANN) approach. Using the RSM, the experimental set is reduced by an order of magnitude; however, a model with R2 = 0.96 is generated with ANN. The predictive model goodness of fit for a single bead is similar to that for the overlapping bead geometry using ANN. Originality/value Developing a bead shape to process parameters model is challenging due to the non-linear coupling between the process parameters and the bead geometry and the number of parameters to be considered. The experimental design and modelling approaches presented in this work illustrate how designed experiments can minimize the data collection and produce a robust predictive model. The output of this work will provide a solid foundation for process planning operations.

State-of-the-art review on laser cladding process as an in-situ repair technique

2021 ◽  
pp. 095440892110445
Author(s):  
Dhiraj Raj ◽  
Saikat R Maity ◽  
Bipul Das
Keyword(s):  
Heat Source ◽  
Laser Cladding ◽  
Process Parameters ◽  
Research Work ◽  
Source Model ◽  
Future Research ◽  
Heat Source Model ◽  
Laser Cladding Process ◽  
Materials Used

The present work reviews the laser cladding process as a repairing technique and the conventional repairing techniques and different heat source models. In this review work, the authors have tried to address the various traditional methods studied for repairing and surface modification. The dominantly used heat source model for numerical modelling of the repairing techniques and the mechanism of the laser cladding process, along with its advantages over the conventional repairing techniques, is also reviewed. This paper also focuses on the predominantly used laser of high power for the cladding process and the effect of process parameters on the quality of the clad layer. The different materials used as clad materials for repairing purposes during the laser cladding process have also been discussed briefly. In this paper, the authors have surveyed literature from different regions of the globe and considered the literature since 1969. This review discusses the various conventional repairing techniques used for repairing, heat source model, process parameters, and different materials used in the laser cladding process. The authors have also briefed the advantages, disadvantages, and application in each of the sections. The use of laser cladding for in-situ repairing process, development of a precise model, use of low-power laser, and application of laser cladding for actual engineering components was also considered in future research work.

Effects of Al2O3 mass fraction on microstructure and friction–wear performance of laser cladded Fe90 alloy coating

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Yan Hu ◽  
Dejun Kong
Keyword(s):  
Wear Resistance ◽  
Laser Cladding ◽  
Wear Mechanism ◽  
Mass Fraction ◽  
Alloy Coating ◽  
High Energy ◽  
Friction Reduction ◽  
Wear Performance ◽  
Content Type ◽  
Wear Rates

Purpose This paper aims to improve the friction reduction and wear resistance of Fe90 alloy coating by the addition of Al2O3. Design/methodology/approach Fe90 alloy coatings with the different Al2O3 mass fractions were prepared on Q235 steel by laser cladding (LC). The morphologies, phases and hardness of Fe90 alloy coating were analyzed using a scanning electron microscope (SEM), X-ray diffraction (XRD) and microhardness tester, respectively. The effects of Al2O3 mass fraction on the coefficient of friction (COF) and wear rates of Fe90 alloy coating were investigated using a friction tester, and the wear model was built to discuss the wear mechanism of Al2O3-reinforced Fe90 alloy coating. Findings The results show that the large number of Fe carbides is generated on the Fe90–Al2O3 coatings by the effect of laser high energy, and the hardness of Fe90–coating is 806 HV0.5, which is 4.48 times of substrate. The average COFs of Fe90–Al2O3 alloy coatings decrease from 0.73 to 0.55, and the wear rates are also reduced from 447.78 to 274.63 µm3•s–1•N–1 by the addition of Al2O3. The Fe90–6% Al2O3 coating presents the highest wear resistance among the three kinds of coatings, and the wear mechanism is abrasive wear and micro-cutting wear. Originality/value The Al2O3-reinforced Fe90 alloy coating was first fabricated by laser cladding, and the effect of Al2O3 on the friction-wear performance of Fe90 alloy coating was investigated.

Multi-objective optimization of wire electrical discharge machining of 20MnCr5 alloy steel

2020 ◽  
Vol 17 (3) ◽  
pp. 325-333
Author(s):  
Naresh Kumar ◽  
Khushdeep Goyal
Keyword(s):  
Surface Roughness ◽  
Alloy Steel ◽  
Process Parameters ◽  
Electric Discharge ◽  
Research Work ◽  
Machining Process ◽  
Content Type ◽  
Taguchi’S Technique ◽  
Pulse Off Time ◽  
Off Time

Purpose Wire electric discharge machining (WEDM) is a non-conventional machining process, which is used to provide difficult and intricate shapes. The purpose of this research work is to apply Taguchi’s technique to optimize the process parameters in WEDM. Alloy steel 20MnCr5 has been selected as base material for experimentation. The effects of the input process parameters such as wire type, pulse-on time, pulse-off time, peak current, wire feed rate and servo voltage have been calculated on the material removal rate (MRR) and surface roughness (Ra) in WEDM operation. Design/methodology/approach In the research work, Taguchi's technique is applied to optimize the process parameters in WEDM. Findings ANOVA indicated that pulse-off time was the most significant factor for the MRR, and servo voltage was the most significant factor for surface roughness (SR). As a part of the project, 20MnCr5 was machined in wire electric discharge machine, and the optimal control parameters were found to get higher MRR and better SR using Taguchi’s technique. Originality/value To the best of authors’ knowledge, after reviewing the literature, materials including alloys of metals such as 16MnCr5 and 20MnCr5 have not been investigated so far, and research regarding machining of these materials is limited. Therefore, 20MnCr5 material has been selected for this research work to generate WEDM data.

Laser Cutting of Aluminium Sheets with a Superficial Cold Spray Titanium Coating

2014 ◽  
Vol 611-612 ◽  
pp. 794-803 ◽  
Author(s):  
Antonello Astarita ◽  
Silvio Genna ◽  
Claudio Leone ◽  
Fabrizio Memola Capece Minutolo ◽  
Valentino Paradiso ◽  
...  
Keyword(s):  
Tool Wear ◽  
Cold Spray ◽  
Process Parameters ◽  
Aluminium Alloys ◽  
Laser Cutting ◽  
Laser Source ◽  
Al Alloy ◽  
Titanium Coating ◽  
Promising Alternative ◽  
Aluminium Sheets

In the manufacturing of metal components both wear and corrosion have to be considered. In particular, corrosion is a primary problem in the aeronautic field, where the aluminium alloys are affected by several corrosion typologies. Furthermore, nowadays carbon fibre reinforced plastics (CFRP) are finding an increasing use, but they can induce galvanic corrosion phenomena when coupled with aluminium alloys. To overcome this problem, corrosion resistant coatings are used on aluminium components. On these premises, the realization of a titanium coating on aluminium components could allow the coupling of CFRP and aluminium alloys, improving the corrosion resistance. Cold Spray Deposition is a recent technology to realize these coatings. This technology allows the production of near fully dense coatings on metallic surfaces. In many applications the coated aluminium sheets have to be machined (cut or drilled). Machining with conventional cutting methods leads to both tool wear and damages in the coating. Laser cutting represents a promising alternative: it does not involve any mechanical cutting force or tool wear and, thanks to the small laser beam spot, it allows to realize complex shapes. In this paper, laser cutting of an Al alloy sheet (0.6 mm thick) coated with Ti Alloy, was studied. The adopted laser source was a 150 W, lamp pumped Nd:YAG, specifically developed for micro-machining operations on metals. During the tests, the process parameters (cutting speed, pulse duration and entrance side) were changed and the kerf geometry was analysed as a function of the process parameters.

Preliminary investigations of rotary ultrasonic neurosurgical bone grinding using Grey-Taguchi optimization methodology

2020 ◽  
Vol 10 (4) ◽  
pp. 479-493 ◽  
Author(s):  
Atul Babbar ◽  
Vivek Jain ◽  
Dheeraj Gupta
Keyword(s):  
Process Parameters ◽  
Feed Rate ◽  
Rotational Speed ◽  
Research Work ◽  
Taguchi Optimization ◽  
Content Type ◽  
Response Characteristics ◽  
Ultrasonic Assisted ◽  
Contour Plots ◽  
Optimization Methodology

PurposeIn present research work, the effects of rotational speed, feed rate and vibration amplitude have been investigated during novel method of ultrasonic-assisted bone grinding. During dissection of tumors, firstly a bone flap is removed near the target region to create passage for grinding burr. During abrasion, heat is produced, which sometimes increases the temperature to unsafe levels. So, efforts have been made to limit the temperature below the threshold levels of osteonecrosis during bone grinding.Design/methodology/approachThe temperature produced during osteotomy has been measured using infrared thermography camera during the implementation of L18 Taguchi orthogonal array design. Subsequently, main effect plots and contour plots have been presented to analyze and visualize the effect of grinding parameters on temperature rise during bone grinding. Furthermore, the process parameters have been optimized for optimum results for response characteristics using Taguchi SN ratio-based optimization methodology. For multiobjective optimization, the process parameters are further optimized using grey relational analysis.FindingsIt is revealed that all three process parameters substantially affect the response characteristics. The proposed optimization methodology is successfully applied on the experimental findings and the optimum results for change in temperature are found to be rotational speed = 3,000 rpm, feed rate = 20 mm/min, amplitude = 10 µm and for standard deviation are 5,000 rpm, 60 mm/min, 10 µm.Research limitations/implicationsThe present research findings cannot be generalized, and researchers are encouraged to further investigate the proposed rotary ultrasonic-assisted bone grinding at higher rotational speed up to 60k rpm on the skull bone.Originality/valueThe research on osteotomy is still at its initial phase, and continuous research is carried out for making patients’ life comfortable. In this direction, the authors have proposed a novel osteotomy method to limit the temperature below the threshold limit of osteonecrosis. The outcomes of the present study will be beneficial for the neurosurgeons working in this field.

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