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Heat treatment of cold-sprayed C355 Al for repair: microstructure and mechanical properties

Murray, J.W.; Zuccoli, M.V.; Hussain, Tanvir

Authors

J.W. Murray

M.V. Zuccoli

Tanvir Hussain



Abstract

Cold gas dynamic spraying of commercially pure aluminum is widely used for dimensional repair in the aerospace sector as it is capable of producing oxide-free deposits of hundreds of micrometer thickness with strong bonding to the substrate, based on adhesive pull-off tests, and often with enhanced hardness compared to the powder prior to spraying. There is significant interest in extending this application to structural, load-bearing repairs. Particularly, in the case of high-strength aluminum alloys, cold spray deposits can exhibit high levels of porosity and microcracks, leading to mechanical properties that are inadequate for most load-bearing applications. Here, heat treatment was investigated as a potential means of improving the properties of cold-sprayed coatings from Al alloy C355. Coatings produced with process conditions of 500 °C and 60 bar were heat-treated at 175, 200, 225, 250 °C for 4 h in air, and the evolution of the microstructure and microhardness was analyzed. Heat treatment at 225 and 250 °C revealed a decreased porosity (~ 0.14% and 0.02%, respectively) with the former yielding slightly reduced hardness (105 versus 130 HV0.05 as-sprayed). Compressive residual stress levels were approximately halved at all depths into the coating after heat treatment, and tensile testing showed an improvement in ductility.

Journal Article Type Article
Journal Journal of Thermal Spray Technology
Print ISSN 1059-9630
Electronic ISSN 1544-1016
Publisher Springer Verlag
Peer Reviewed Peer Reviewed
APA6 Citation Murray, J., Zuccoli, M., & Hussain, T. (in press). Heat treatment of cold-sprayed C355 Al for repair: microstructure and mechanical properties. Journal of Thermal Spray Technology, https://doi.org/10.1007/s11666-017-0665-z
DOI https://doi.org/10.1007/s11666-017-0665-z
Keywords Aluminum alloys; Cold spray; Heat treatment; Repair; Solution heat treatment
Publisher URL https://doi.org/10.1007/s11666-017-0665-z
Copyright Statement Copyright information regarding this work can be found at the following address: http://creativecommons.org/licenses/by/4.0

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Copyright Statement
Copyright information regarding this work can be found at the following address: http://creativecommons.org/licenses/by/4.0





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