Enhanced erosion performance of cold spray co-deposited AISI316 MMCs modified by friction stir processing

Tom Peat, Alexander Galloway, Athanasios Toumpis, Russell Steel, Wenzhong Zhu, Naveed Iqbal

Research output: Contribution to journalArticle

27 Citations (Scopus)
22 Downloads (Pure)

Abstract

The present study reports on the erosion properties of a novel surface engineering process combining cold spray and friction stir processing. Tungsten carbide (WC-CoCr) and aluminium oxide (Al2O3) powders were cold spray co-deposited with AISI316 using a twin powder feed system. The deposited coatings were subsequently friction stir processed to refine and redistribute the reinforcing particles and remove the coating-to-substrate interface layer, thus generating a new metal matrix composite surface. Microstructural analysis of the SprayStirred (cold sprayed then friction stirred) specimens revealed significant particle refinement and improved particle distribution over the as-deposited coatings. The erosion performance of these SprayStirred surfaces was evaluated using a flowing slurry and demonstrated an 80% decrease in volume loss over the as-received AISI316 at 30° angle of attack. For SprayStirred WC-CoCr, microhardness measurements indicated an increase of approx. 530% over the unaltered AISI316 and 100% over the cold sprayed coating. These findings highlight the considerable increase in erosion performance of the SprayStirred specimens, and thus demonstrate the benefits of this innovative surface engineering process. This outcome is attributed to dispersion strengthening, imparted by the refined tungsten carbides. Furthermore, the SprayStirred WC-CoCr coating exhibited an 85% reduction in volume loss over an HVOF sprayed WC-CoCr coating.

Original languageEnglish
Pages (from-to)22-35
Number of pages14
JournalMaterials and Design
Volume120
Early online date3 Feb 2017
DOIs
Publication statusPublished - 15 Apr 2017
Externally publishedYes

Bibliographical note

NOTICE: this is the author’s version of a work that was accepted for publication in Materials and Design. Changes resulting from the publishing process, such as peer review, editing, corrections, structural formatting, and other quality control mechanisms may not be reflected in this document. Changes may have been made to this work since it was submitted for publication. A definitive version was subsequently published in Materials and Design [120], (2017) DOI: https://dx.doi.org/10.1016/j.matdes.2017.01.099

© 2017, Elsevier. Licensed under the Creative Commons Attribution-
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Copyright © and Moral Rights are retained by the author(s) and/ or other copyright owners. A copy can be downloaded for personal non-commercial research or study, without prior permission or charge. This item cannot be reproduced or quoted extensively from without first obtaining permission in writing from the copyright holder(s). The content must not be changed in any way or sold commercially in any format or medium without the formal permission of the copyright holders.

Keywords

  • AlO
  • Cold spray
  • Friction stir processing
  • Metal matrix composite
  • Slurry erosion
  • WC-CoCr

ASJC Scopus subject areas

  • Materials Science(all)
  • Mechanics of Materials
  • Mechanical Engineering

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