Cold gas dynamic spraying of metal matrix composite coatings with subsequent friction stir processing

Tom Peat, Alexander Galloway, Athanasios Toumpis, Philip McNutt, Naveed Iqbal

Research output: Contribution to conferencePaper

Abstract

The present study forms an initial investigation in to the development of an innovative process to apply wear resistant surface layers to a chosen substrate material. Tungsten carbide – cobalt chromium, chromium carbide – nickel chromium and aluminium oxide coatings were cold spray deposited on to AA5083 grade aluminium and subsequently friction stir processed. In order to improve the deposition efficiency of the cold spray process, coatings were co-deposited with powdered AA5083. Friction stir processing (FSP) has been used in combination with the cold spray deposited coating to produce an engineered surface layer containing evenly dispersed reinforcing particles that reflects the constituent phases of the feedstock powder. Microstructural characterisation was performed on the test specimens making use of micro-hardness testing, light optical and scanning electron microscopy with electron dispersive spectroscopy to establish the elemental composition of the processed layer. The resulting data was contrasted with as-deposited coatings (no FSP) to highlight the variation in microstructure between the two conditions.
The results demonstrate that FSP has improved the dispersal of reinforcing particles within the metal matrix composite layer with the average interparticle spacing decreasing by up to 68%. The micro-hardness of friction stir processed material shows an increase of approximately 540% over the unaltered substrate and 118% increase over the as-deposited MMC layer, in the case of the tungsten carbide reinforced coating.

Conference

Conference11th International Symposium on Friction Stir Welding
Abbreviated title11ISFSW
CountryUnited Kingdom
CityCambridge
Period17/05/1619/05/16
Internet address

Fingerprint

Gas dynamics
Composite coatings
Spraying
Metals
Friction
Coatings
Processing
Chromium
Tungsten carbide
Microhardness
Hardness testing
Aluminum
Aluminum Oxide
Substrates
Cobalt
Powders
Feedstocks
Carbides
Nickel
Wear of materials

Keywords

  • wear resistant surface layers
  • cold spray process
  • friction stir processing
  • f microhardness testing
  • cermet
  • metallic binder
  • ceramic coatings

Cite this

Peat, T., Galloway, A., Toumpis, A., McNutt, P., & Iqbal, N. (2016). Cold gas dynamic spraying of metal matrix composite coatings with subsequent friction stir processing. 1-15. Paper presented at 11th International Symposium on Friction Stir Welding, Cambridge, United Kingdom.
Peat, Tom ; Galloway, Alexander ; Toumpis, Athanasios ; McNutt, Philip ; Iqbal, Naveed. / Cold gas dynamic spraying of metal matrix composite coatings with subsequent friction stir processing. Paper presented at 11th International Symposium on Friction Stir Welding, Cambridge, United Kingdom.15 p.
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Peat, T, Galloway, A, Toumpis, A, McNutt, P & Iqbal, N 2016, 'Cold gas dynamic spraying of metal matrix composite coatings with subsequent friction stir processing' Paper presented at 11th International Symposium on Friction Stir Welding, Cambridge, United Kingdom, 17/05/16 - 19/05/16, pp. 1-15.

Cold gas dynamic spraying of metal matrix composite coatings with subsequent friction stir processing. / Peat, Tom; Galloway, Alexander; Toumpis, Athanasios; McNutt, Philip; Iqbal, Naveed.

2016. 1-15 Paper presented at 11th International Symposium on Friction Stir Welding, Cambridge, United Kingdom.

Research output: Contribution to conferencePaper

TY - CONF

T1 - Cold gas dynamic spraying of metal matrix composite coatings with subsequent friction stir processing

AU - Peat, Tom

AU - Galloway, Alexander

AU - Toumpis, Athanasios

AU - McNutt, Philip

AU - Iqbal, Naveed

PY - 2016/8/8

Y1 - 2016/8/8

N2 - The present study forms an initial investigation in to the development of an innovative process to apply wear resistant surface layers to a chosen substrate material. Tungsten carbide – cobalt chromium, chromium carbide – nickel chromium and aluminium oxide coatings were cold spray deposited on to AA5083 grade aluminium and subsequently friction stir processed. In order to improve the deposition efficiency of the cold spray process, coatings were co-deposited with powdered AA5083. Friction stir processing (FSP) has been used in combination with the cold spray deposited coating to produce an engineered surface layer containing evenly dispersed reinforcing particles that reflects the constituent phases of the feedstock powder. Microstructural characterisation was performed on the test specimens making use of micro-hardness testing, light optical and scanning electron microscopy with electron dispersive spectroscopy to establish the elemental composition of the processed layer. The resulting data was contrasted with as-deposited coatings (no FSP) to highlight the variation in microstructure between the two conditions. The results demonstrate that FSP has improved the dispersal of reinforcing particles within the metal matrix composite layer with the average interparticle spacing decreasing by up to 68%. The micro-hardness of friction stir processed material shows an increase of approximately 540% over the unaltered substrate and 118% increase over the as-deposited MMC layer, in the case of the tungsten carbide reinforced coating.

AB - The present study forms an initial investigation in to the development of an innovative process to apply wear resistant surface layers to a chosen substrate material. Tungsten carbide – cobalt chromium, chromium carbide – nickel chromium and aluminium oxide coatings were cold spray deposited on to AA5083 grade aluminium and subsequently friction stir processed. In order to improve the deposition efficiency of the cold spray process, coatings were co-deposited with powdered AA5083. Friction stir processing (FSP) has been used in combination with the cold spray deposited coating to produce an engineered surface layer containing evenly dispersed reinforcing particles that reflects the constituent phases of the feedstock powder. Microstructural characterisation was performed on the test specimens making use of micro-hardness testing, light optical and scanning electron microscopy with electron dispersive spectroscopy to establish the elemental composition of the processed layer. The resulting data was contrasted with as-deposited coatings (no FSP) to highlight the variation in microstructure between the two conditions. The results demonstrate that FSP has improved the dispersal of reinforcing particles within the metal matrix composite layer with the average interparticle spacing decreasing by up to 68%. The micro-hardness of friction stir processed material shows an increase of approximately 540% over the unaltered substrate and 118% increase over the as-deposited MMC layer, in the case of the tungsten carbide reinforced coating.

KW - wear resistant surface layers

KW - cold spray process

KW - friction stir processing

KW - f microhardness testing

KW - cermet

KW - metallic binder

KW - ceramic coatings

UR - http://www.fswsymposium.co.uk/

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Peat T, Galloway A, Toumpis A, McNutt P, Iqbal N. Cold gas dynamic spraying of metal matrix composite coatings with subsequent friction stir processing. 2016. Paper presented at 11th International Symposium on Friction Stir Welding, Cambridge, United Kingdom.