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

17 Citations (Scopus)

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.
LanguageEnglish
Pages22-35
Number of pages14
JournalMaterials & Design
Volume120
Early online date3 Feb 2017
DOIs
Publication statusPublished - 15 Apr 2017

Fingerprint

Erosion
Friction
Processing
Coatings
Tungsten carbide
Powders
Sprayed coatings
Aluminum Oxide
Angle of attack
Microhardness
Metals
Aluminum
Oxides
Composite materials
Substrates

Keywords

  • friction stir processing
  • cold spray
  • metal matrix composite
  • slurry erosion
  • WC-CoCr
  • Al2O3
  • tungsten carbide
  • aluminum oxide

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.",
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Enhanced erosion performance of cold spray co-deposited AISI316 MMCs modified by friction stir processing. / Peat, Tom; Galloway, Alexander; Toumpis, Athanasios; Steel, Russell; Zhu, Wenzhong; Iqbal, Naveed.

In: Materials & Design, Vol. 120, 15.04.2017, p. 22-35.

Research output: Contribution to journalArticle

TY - JOUR

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

PY - 2017/4/15

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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.

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KW - slurry erosion

KW - WC-CoCr

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KW - tungsten carbide

KW - aluminum oxide

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