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Effect of Substrate Surface Roughness on Microstructure and Mechanical Properties of Cold-Sprayed Ti6Al4V Coatings on Ti6Al4V Substrates

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Abstract

Surface condition, especially surface roughness of substrates, critically influences the adhesion of cold-sprayed titanium alloy coatings. To study this, Ti6Al4V (Ti64) coatings were deposited on Ti64 substrates with increasing surface roughness (Ra) from 0.05 µm (polished surface) to 5.4 µm (water-jet cut surface). It was found that the substrate surface roughness did not significantly affect the porosity, hardness and coating surface roughness because these properties were dependent on the deposition parameters such as propellant gas pressure and temperature and nozzle traverse speed. The adhesion test results showed that smoother substrate surfaces improved the coating bond strength of the cold-sprayed Ti64 coatings from about 7.1 MPa (Ra: 5.4 µm, interface failure) to 68.7 MPa (Ra: 0.05 µm, glue failure). The fracture characteristics of the debonded coating/substrate interfaces revealed that there were more adiabatic shear-induced craters observed on the smoother substrate surfaces. Finite element modeling also showed that the substrate surface features (i.e., peaks and valleys) possibly prevented the intimate contact between the particles and substrate and thus induced the non-uniform distributions of temperature, stress and strain at the particle/substrate interface.

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Acknowledgments

This work was financially supported by the National Research Foundation (NRF), Rolls-Royce (RR) and Nanyang Technological University (NTU), Singapore, with the research grant (ARMS 1.1 Advanced metalized coatings using cold spray project).

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Authors and Affiliations

  1. Rolls-Royce@NTU Corporate Lab, Nanyang Technological University, 50 Nanyang Avenue, Singapore, 639798, Singapore

    Adrian Wei-Yee Tan, Wen Sun, Ayan Bhowmik, Feng Li, Iulian Marinescu & Erjia Liu

  2. School of Mechanical and Aerospace Engineering, Nanyang Technological University, 50 Nanyang Avenue, Singapore, 639798, Singapore

    Adrian Wei-Yee Tan, Wen Sun, Ayan Bhowmik, Han Zheng & Erjia Liu

  3. Facility for Analysis, Characterisation, Testing and Simulation (FACTS), Nanyang Technological University, Singapore, 639798, Singapore

    Jun Yan Lek

  4. School of Mechanical and Automation Engineering, Chinese University of Hong Kong, William M.W. Mong Engineering Building, Shatin, Hong Kong

    Xu Song

  5. Singapore Institute of Manufacturing Technology (SIMTech), 73 Nanyang Drive, Singapore, 637662, Singapore

    Wei Zhai & Han Zheng

  6. Central Technology Group, Rolls-Royce Singapore Pte Ltd, 1 Seletar Aerospace Crescent, Singapore, 797575, Singapore

    Feng Li & Iulian Marinescu

  7. School of Materials Science and Engineering, Nanyang Technological University, 50 Nanyang Avenue, Singapore, 639798, Singapore

    Zhili Dong

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  1. Adrian Wei-Yee Tan
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Tan, A.WY., Sun, W., Bhowmik, A. et al. Effect of Substrate Surface Roughness on Microstructure and Mechanical Properties of Cold-Sprayed Ti6Al4V Coatings on Ti6Al4V Substrates. J Therm Spray Tech 28, 1959–1973 (2019). https://doi.org/10.1007/s11666-019-00926-5

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