Post-Process Treatments on Supersonic Cold Sprayed Coatings: A Review
Abstract
:1. Introduction
2. Heat Treatment
3. Friction-Stir Processing Treatment
4. Shot Peening Treatment
5. Laser Re-Melting Treatment
6. Other Post-Process Treatments
7. Summary and Outlook
Author Contributions
Funding
Acknowledgments
Conflicts of Interest
References
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Coatings | References | HT Parameters | Main Findings |
---|---|---|---|
Cu | [24] | Temperature: 300 °C Duration: 1 h Atmosphere: vacuum, air | The electrical conductivity of the coatings after HT was comparable to bulk materials. Vacuum condition during HT yielded lower porosity and higher conductivity of the coatings. |
Cu | [29] | Temperature: 300–700 °C Duration: 3 h Atmosphere: Ar | The microstructural and mechanical anisotropies in the coatings were relieved after HT. HT could effectively decrease the anisotropy of tensile strength. While, its effect on elongation anisotropy was very limited. |
Cu-4Cr-2Nb | [30] | Temperature: 250–950 °C Duration: 2 h Atmosphere: vacuum | The microhardness of the coatings was the highest after HT at 350 °C due to the formation of Cr2Nb and gradually decreased with increasing HT temperature due to coarsening of the Cr2Nb phase and softening of the Cu matrix. |
Al6061 | [31] | Temperature: 176 °C Duration: 1 h, 8 h Atmosphere: air | After HT, the UTS of the coatings was improved because of the formation of strengthening precipitates and the localized improvement in metallurgical bonding. |
Al-25Ni Al-25Ti | [32] | Temperature: 450–630 °C Duration: 4 h Atmosphere: N2 | Well dispersed intermetallic compounds were formed in the coatings after HT, leading to increased hardness of the coatings. |
Al | [23] | Temperature: 400 °C Duration: 20 h Atmosphere: Ar | An Al3Mg2 or Mg17Al12 intermetallic compound layer was formed at the coating/substrate interface, which was significantly harder than the aged AZ91 alloy and offered a corrosion resistance similar to that of the Al alloys. |
Fe-40Al | [33] | Temperature: 650–1100 °C Duration: 5 h Atmosphere: Ar | After HT, a Fe-Al intermetallic compound was formed within the coating, and the erosion resistance of the coating increased since the erosion mechanism was converted from spalling off to micro-cutting and ploughing of erosive particles. |
SS316L | [26] | Temperature: 1000 °C Duration: 4–8 h Atmosphere: Air, vacuum | Enhanced mechanical properties of the coatings were mainly dominated by improved inter-particle bonding and particle grain structure rather than reduction of porosity. Air annealing only slightly improved the tensile strength and ductility of the SS316L deposits. Vacuum annealing significantly improved the tensile strength and ductility of the SS613L deposits. |
SS304 | [34] | Temperature: 600–950 °C Duration: 1 h Atmosphere: vacuum | Annealing treatment healed up the weakly bonded interfaces and changed the particle bonding mechanism from mechanical interlocking to metallurgical bonding under certain annealing conditions. |
Ti | [27] | Temperature: 600 °C Duration: 1 h Atmosphere: vacuum, Ar, 5%H2 + Ar | Among the three HT environments, vacuum could promote the highest hardness and the lowest porosity of the coatings. |
Ti | [35] | Temperature: 850 °C Duration: 4 h Atmosphere: Ar | Micro-CT analysis showed that the majority of the pores in the coatings after HT were smaller than those in the as-sprayed coatings. |
Ti-WC | [36] | Temperature: 550–650 °C Duration: 1 h Atmosphere: Ar | After HT, coating porosity dropped. The hardness and wear resistance of the coatings increased due to the formation of TiC phase. |
IN718 | [37] | Temperature: 900 °C Duration: 10 min Atmosphere: vacuum | Compared with traditional furnace HT, eddy current HT was used, which was more efficient in promoting atomic diffusion and mass transport between the particles in the coatings, thus leading to a higher strength of the coatings. |
IN718 | [38] | Temperature: 990 °C Duration: 4 h Atmosphere: Ar | A high-performance of the coatings after HT was achieved with the adhesive strength between coatings and substrates being comparable with the tensile strength of the bulk materials after HT. |
IN718 | [39] | Temperature: 950-1250 °C Duration: 1–2 h Atmosphere: 10% H2 + Ar | The ultimate tensile strength of the coatings after HT was about 62% of that of the bulk materials and the elongation of the coatings exceeded that of the bulk materials. |
Nb | [25] | Temperature: 500–1250 °C Duration: 1 h Atmosphere: Ar | After HT, coating porosity was eliminated, and inter-particle boundaries in the coatings were closed. The elastic modulus and tensile strength of the coatings were close to those of the bulk materials after HT at above 1250 °C. |
Ni/FeSiAl | [40] | Temperature: 200–800 °C Duration: 2 h Atmosphere: Ar | The soft magnetic performance of the coatings was significantly improved via stress relief and grain growth after proper HT. |
Coatings | References | FSP Parameters | Main Findings |
---|---|---|---|
AA7075 | [60] | Shoulder diameter: 12 mm; Concave shoulder angle: 3°; Pin diameter: 1.7 mm; Pin height: 1.5 mm | After FSP, the hardness of the coatings was improved by three times and the coating/substrate bonding strength was improved by material intermixing. |
AA2024/Al2O3 composite | [61] | Stir tool material: H13 steel; Shoulder diameter: 10 mm; Concave shoulder angle: 2.5°; Pin diameter: 3.4 mm; Pin height: 2.9 mm; Rotation speed: 900 rpm; Traverse speed: 50 mm/min | FSP significantly reduced the Al2O3 particles size and effectively enhanced the corrosion resistance of the coatings. |
AA2024/Al2O3 | [62] | Stir tool material: H13 steel; Concave shoulder angle: 2.5°; Shoulder diameter: 10 mm; Pin diameter: 2.9 mm; Pin height: 3.4 mm; Rotation speed: 900–1500 rpm; Traverse speed: 100 mm/min | The fragmentation level increased with rotation speed. FSP could effectively improve the UTS and elongation of the MMC coatings. |
WC-CoCr/Al2O3 (Cr3C2-NiCr/Al2O3) | [56] | Stir tool material: H13 steel; Concave shoulder angle: 3°; Pin diameter: 2 mm; Pin height: 2 mm; Rotation speed: 600 rpm; Traverse speed: 272 mm/min | FSP resulted in substantial refinement of the reinforcing particles and reduced interparticle spacing for each reinforcing particle and increased the average hardness of the coatings. |
WC-CoCr/Al2O3 | [57] | Stir tool material: W-Re/pcBN; Concave shoulder angle: 2°/0; Shoulder diameter: 18 mm /25.4 mm; Pin diameter: 5 mm; Pin height: 5.7 mm/5.75 mm; Rotation speed: 250 rpm/800 rpm; Traverse speed: 100 mm/min/76 mm/min | FSP resulted in the dispersion of the as-deposited WC-CoCr agglomerates and refinement of the Al2O3 particles. FSP improved the hardness homogeneity as well as the anti-erosion performance of the coatings. |
Ti | [63] | Stir tool material: WC; Concave shoulder angle: 2.5°; Shoulder diameter: 12 mm; Rotation speed: 900 rpm; Traverse speed: 630 mm/min | FSP aided the formation of a titanium aluminide (Al3Ti) intermetallic layer at the Ti coating/Al substrate interface. |
Cu60-Zn40 | [59] | Concave shoulder angle: 2.5°; Shoulder diameter: 10 mm; Pin diameter: 3.4 mm; Pin height: 1.5 mm; Rotation speed: 1500 rpm; Traverse speed: 100 mm/min | The friction-stirred coatings contained mainly HAGBs and twin boundaries with the tensile strength of coating improved. |
Ni50-Ti50 | [64] | Stir tool material: W-Re Concave shoulder angle: 2.5°; Shoulder diameter: 15 mm; Rotation speed: 1500 rpm; Traverse speed: 100 mm/min | After FSP, Ni-Ti intermetallic compounds were formed, leading to the significantly improved microhardness and wear resistance of the coatings. |
SiCp/Al5056 | [58,65] | Stir tool material: W-Re; Concave shoulder angle: 2.5°; Shoulder diameter: 10 mm; Pin diameter: 3.4 mm; Pin height: 2.9 mm; Rotation speed: 600–1400 rpm; Traverse speed: 100 mm/min | After FSP, fragmented SiC particles were homogenously distributed in the coatings. The Al matrix particles were substantially refined to form the fine and equiaxed grains. The microhardness and anti-friction performance of the coatings were improved. |
Al–Al2O3 | [66] | Stir tool material: W-Re; Concave shoulder angle: 3°; Shoulder diameter: 12 mm; Rotation speed: 894–1723 rpm; Traverse speed: 88 mm/min | After FSP, the coating hardness increased due to the re-distribution of the Al2O3 particles in the coatings. |
Coatings | References | SP Parameters | Main Findings |
---|---|---|---|
Pure Al and Al/Al2O3 composite coatings | [71] | Ball Material: S230 cast iron | Shot peening was not able to considerably influence the residual stress state of the coatings. The application of shot peening was able to induce work hardening to the coating top layer. |
Diameter: 0.6 mm | |||
Stand-of-Distance: 380 mm | |||
Pressure: 1.5 bar | |||
Exposure time: 33 s | |||
Coverage: 200% | |||
Al 6082 | [72] | Ball Material: S230 cast iron | Post shot peening could not induce compressive residual stresses in the coatings. Instead, the peening caused damage in the coatings due to the presence of weakly bonded particles. The conventional or severe shot peening as post-treatment was not able to increase the fatigue strength of the coated specimens. |
Diameter: 0.6 mm | |||
Stand-of-Distance: 380 mm | |||
Intensity: “Almen A” strip with 6-8 | |||
(thousandth of an inch) | |||
Coverage: 100% and 800% | |||
NiCrAlY | [73] | Ball Material: glass bead grit | The surface roughness of the coatings was significantly reduced after shot peening, which promoted the formation of a uniform oxide layer on the coating surfaces. |
Diameter: 0.3 mm | |||
Stand-of-Distance: 150 mm |
Coatings | References | LR Parameters | Main Findings |
---|---|---|---|
Ti | [81,82] | Spot diameter: 2 mm | After LR, three different metallurgical zones were observed: a re-melted zone (RZ), a heat affected zone (HAZ) and the base material (BM). |
Scan speed: 10–1000 mm/s | |||
Laser power: 200 W | |||
CP-Ti grade 2 | [83] | Spot diameter: 0.3–1.08 mm | The laser-treated regions were pore-free with the equiaxed grains. The laser-treated Ti coatings performed like a high-quality barrier layer that improved their anti-corrosion performance. |
Scan speed: 21.6–48.3 mm/s | |||
Laser power: 440–1000 W | |||
Ti-6Al-4V | [80] | Spot diameter: 1 mm | The laser treated Ti64 coatings with a higher laser power had a higher surface hardness. The tribological properties of the laser treated Ti64 coatings were significantly influenced by the laser power. |
Scan speed: 20 mm/s | |||
Laser power: 50–200 W | |||
Al | [85] | Spray distance: 250 mm | After LR, the fine porosities and micro-cracks in the coatings were eliminated, and the grains were refined. The Al coating hardness and wear resistance were enhanced after LR. |
Spot diameter: 5 mm | |||
Laser power: 800 W | |||
Flow rate of Ar gas: 8 L/min | |||
Inconel 625 | [84] | Scan speed: 25–50 mm/s | After LR, the coating porosity was reduced and the coating elastic modulus increased, while the coating hardness was reduced due to the formation of a columnar dendritic microstructure. |
Heat input: 14–28 J/mm | |||
Laser power: 700 W | |||
Al-Si coating | [86] | Spot diameter: 40 µm | After LR, the coating microstructure was significantly refined, and the coating surface roughness was lowered. An Al phase supersaturated with Si was formed in the coatings after FSP. |
Hatch distance: 50 µm | |||
Scan speed: 1000 mm/s | |||
Laser power: 200–300 W |
Laser Scan Speed (mm/s) | Microhardness (HV) | ||
---|---|---|---|
RZ | HAZ | BM | |
200 | 480 | 130 | 160 |
400 | 475 | 134 | |
600 | 485 | 128 | |
800 | 468 | 125 | |
1000 | 473 | 135 |
Coatings | References | Post Process | Parameters | Main Findings |
---|---|---|---|---|
B4C/Al | [88] | Hot rolling | Heating: ~500 °C for 2 h Rolling: unidirectional at a rolling speed of 0.03 m/s | After hot rolling, recrystallized grains and sub-structured grains were formed in the coatings. The tensile strength and elongation of the rolled coatings were much higher than those of the as-sprayed and conventionally heat-treated coatings. |
Si/A380 | [89] | Hot rolling | Heating: ~500 °C for 2 h Rolling: unidirectional at a rolling speed of 0.03 m/s | After hot rolling, the reinforcement Si particles were refined and uniformly distributed in the Al matrix. The UTS and elongation of the rolled coatings were significantly improved compared to those of the as-sprayed and conventionally heat-treated coatings. |
B4C/Al | [90] | Hot compression + Hot rolling | Hot compression: ~500 °C with speed of 0.05 mm/min Hot rolling: ~500 °C for 2 h, followed by rolling speed at 0.03 m/s. | After the hybrid treatment, the Al grains were extensively refined and the B4C particles were homogeneously distributed in the matrix. The tensile strength and elongation of the coatings were simultaneously improved. |
17-4PH stainless steel | [91] | Finish turning and ball-burnishing | Finish turning: tungsten carbide tool, cutting speed (50 m/min), feed rate (0.15 mm/rev), depth of cut (0.3 mm). Ball-burnishing: ceramic ball (6 mm diameter), feed (0.05 mm/rev), speed (50 m/min) and load (250 N) | Applying finish turning or ball-burnishing operation affected the near-surface microstructure, resulting in a transformed layer in the coatings. After finish turning, tensile residual stresses were induced at the coating surface. After ball-burnishing, the surface tensile stresses were turned into compressive residual ones. |
Ti64 | [95] | HIP | Temperature: 920 °C Pressure: 120 MPa Duration: 2 h Gas: Ar | After HIP, the coating porosity was significantly reduced, and the tensile strength of the coatings increased from 150 MPa to 650 MPa. |
Pure Ti | [96] | HIP | Temperature: 900 °C Pressure: 110 MPa Gas: Ar | After HIP, the coating porosity was decreased from 4.3 to 2.2% and the UTS of the coatings was increased from 110 to 480 MPa. |
316L | [26] | HIP | Temperature: 1000 °C Pressure: 150 MPa Gas: Ar Duration: 4 h | After HIP, the coating porosity was significantly decreased and the UTS of the coatings was increased. However, the mechanical properties of HIPed samples did not surpass those of the vacuum-annealed samples. |
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Sun, W.; Tan, A.W.-Y.; Wu, K.; Yin, S.; Yang, X.; Marinescu, I.; Liu, E. Post-Process Treatments on Supersonic Cold Sprayed Coatings: A Review. Coatings 2020, 10, 123. https://doi.org/10.3390/coatings10020123
Sun W, Tan AW-Y, Wu K, Yin S, Yang X, Marinescu I, Liu E. Post-Process Treatments on Supersonic Cold Sprayed Coatings: A Review. Coatings. 2020; 10(2):123. https://doi.org/10.3390/coatings10020123
Chicago/Turabian StyleSun, Wen, Adrian Wei-Yee Tan, Kaiqiang Wu, Shuo Yin, Xiawei Yang, Iulian Marinescu, and Erjia Liu. 2020. "Post-Process Treatments on Supersonic Cold Sprayed Coatings: A Review" Coatings 10, no. 2: 123. https://doi.org/10.3390/coatings10020123
APA StyleSun, W., Tan, A. W.-Y., Wu, K., Yin, S., Yang, X., Marinescu, I., & Liu, E. (2020). Post-Process Treatments on Supersonic Cold Sprayed Coatings: A Review. Coatings, 10(2), 123. https://doi.org/10.3390/coatings10020123