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

doi:10.1016/j.matdes.2017.01.099

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

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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 language	English
Pages (from-to)	22-35
Number of pages	14
Journal	Materials and Design
Volume	120
Early online date	3 Feb 2017
DOIs	https://doi.org/10.1016/j.matdes.2017.01.099
Publication status	Published - 15 Apr 2017
Externally published	Yes

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-
NonCommercial-NoDerivatives 4.0 International
http://creativecommons.org/licenses/by-nc-nd/4.0/
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

General Materials Science
Mechanics of Materials
Mechanical Engineering

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10.1016/j.matdes.2017.01.099

Post-printAccepted author manuscript, 1.65 MBLicence: CC BY-NC-ND

Cite this

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

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.",

keywords = "AlO, Cold spray, Friction stir processing, Metal matrix composite, Slurry erosion, WC-CoCr",

author = "Tom Peat and Alexander Galloway and Athanasios Toumpis and Russell Steel and Wenzhong Zhu and Naveed Iqbal",

note = "NOTICE: this is the author{\textquoteright}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 {\textcopyright} 2017, Elsevier. Licensed under the Creative Commons Attribution- NonCommercial-NoDerivatives 4.0 International http://creativecommons.org/licenses/by-nc-nd/4.0/ Copyright {\textcopyright} 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. ",

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T1 - Enhanced erosion performance of cold spray co-deposited AISI316 MMCs modified by friction stir processing

AU - Peat, Tom

AU - Galloway, Alexander

AU - Toumpis, Athanasios

AU - Steel, Russell

AU - Zhu, Wenzhong

AU - Iqbal, Naveed

N1 - 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- NonCommercial-NoDerivatives 4.0 International http://creativecommons.org/licenses/by-nc-nd/4.0/ 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.

PY - 2017/4/15

Y1 - 2017/4/15

N2 - 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.

AB - 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.

KW - AlO

KW - Cold spray

KW - Friction stir processing

KW - Metal matrix composite

KW - Slurry erosion

KW - WC-CoCr

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DO - 10.1016/j.matdes.2017.01.099

M3 - Article

AN - SCOPUS:85011628816

SN - 0264-1275

VL - 120

SP - 22

EP - 35

JO - Materials and Design

JF - Materials and Design

ER -

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

Abstract

Bibliographical note

Keywords

ASJC Scopus subject areas

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