SpringerLink
Log in

Iron-based Surfacing Alloy Composite Coatings Deposited on Al7075 Substrate Using Cold Spraying and Its Properties

  • Peer Reviewed
  • Published:
Journal of Thermal Spray Technology Aims and scope Submit manuscript

Abstract

In this study, the low-cost and high-wear-resistant iron-based surfacing alloy powder is used to prepare composite coatings on the 2 mm thick Al7075 substrate with different volume ratios of Al6061 powder (3:4, 5:4 and 2:1) by the low pressure cold spray equipment. The thickness of composite coatings increases with the increasing in preheating temperature and is approximately 60-80 μm thick in single pass. The percentage of iron-based surfacing alloy powder increased with the decrease in the proportion of Al6061 powder. The microhardness and bonding strength of the coatings increase with the increase in the percentage of surfacing alloy powder due to the tam** and work-hardening effect. The wear mechanism of cold sprayed composite coatings involves both abrasive and adhesive wear on the worn surface under different loads. The wear mechanism of the micro-arc oxidation sample transforms via abrasive wear to abrasive and adhesive wear as the load changes from 5 to 10 N. Investigation about wear properties reveals that the micro-arc sample has better wear resistance at the load of 5 N, but the cold sprayed composite coatings have better wear resistance at 10 N. The Al2O3 layer is worn out and the substrate is exposed during sliding for micro-arc oxidation samples at the higher load. The results indicate that the low pressure cold spraying may replace the micro-arc oxidation technique under the higher load condition in industrial applications.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Subscribe and save

Springer+ Basic
EUR 32.99 /Month
  • Get 10 units per month
  • Download Article/Chapter or Ebook
  • 1 Unit = 1 Article or 1 Chapter
  • Cancel anytime
Subscribe now

Buy Now

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12

Similar content being viewed by others

References

  1. D.S. Mehta, S.H. Masood and W.Q. Song, Investigation of Wear Properties Of Magnesium and Aluminum Alloys for Automotive Applications, J. Mater. Process. Tech., 2004, 155, p 1526-1531.

    Article  Google Scholar 

  2. J. Hirsch and T. Al-Samman, Superior Light Metals by Texture Engineering: Optimized Aluminum and Magnesium Alloys for Automotive Applications, Acta Mater., 2013, 61, p 818-843.

    Article  CAS  Google Scholar 

  3. G.K. Ramesh, S.A. Shehzad, A. Rauf and A.J. Chamkha, Heat transport Analysis of Aluminum Alloy and Magnetite Graphene Oxide Through Permeable Cylinder with Heat Source/Sink, Phys. Scripta, 2020, 95, p 095203.

    Article  CAS  Google Scholar 

  4. R. Chandel, N. Sharma and S.A. Bansal, A Review on Recent Developments of Aluminum-Based Hybrid Composites for Automotive Applications, Emerg. Mater., 2021, 4, p 1243-1257.

    Article  CAS  Google Scholar 

  5. S.R. Kandavalli, G.B. Rao, P.K. Bannaravuri, M.M.K. Rajam, S.R. Kandavalli and S.R. Ruban, Surface Strengthening of Aluminium Alloys/Composites by Laser Applications: A Comprehensive Review, Mater. Today: Proc., 2021, 47, p 6919-6925.

    CAS  Google Scholar 

  6. J. Evertsson, F. Bertram, F. Zhang, L. Rullik, L.R. Merte, M. Shipilin, M. Soldemo, S. Ahmadi, N. Vinogradov, F. Carlà, J. Weissenrieder, M. Göthelid, J. Pan, A. Mikkelsen, J.-O. Nilsson and E. Lundgren, The Thickness of Native Oxides on Aluminum Alloys and Single Crystals, Appl. Surf. Sci., 2015, 349, p 826-832.

    Article  CAS  Google Scholar 

  7. C. **g, R. Wang, F. Zhao, L. Zhang, Q. He and X. Tong, Preparation of 1060, 2024 and 7075 Aluminum Alloy Anodic Oxide Films, Coatings, 2021, 11, p 1498.

    Article  CAS  Google Scholar 

  8. J.W. Diggle, T.C. Downie and C.W. Goulding, Anodic Oxide Films on Aluminum, Chem. Rev., 1969, 69, p 65-405.

    Article  Google Scholar 

  9. K. **, H. Wu, C. Zhou, Z. Qi, K. Yang, R.K. Fu, S. **ao, G.S. Wu, K.J. Ding, G.H. Chen and P.K. Chu, Improved Corrosion and Wear Resistance of Micro-Arc Oxidation Coatings on the 2024 Aluminum Alloy by Incorporation of Quasi-Two-Dimensional Sericite Microplates, Appl. Surf. Sci., 2022, 585, p 152693.

    Article  CAS  Google Scholar 

  10. J. Tian, Z. Luo, S. Qi and X. Sun, Structure and Antiwear Behavior of Micro-Arc Oxidized Coatings on Aluminum Alloy, Surf. Coat. Technol., 2002, 154, p 1-7.

    Article  CAS  Google Scholar 

  11. Y.K. Gao, Improvement of Fatigue Property in 7050-T7451 Aluminum Alloy by Laser Peening and Shot Peening, Mat. Sci. Eng. A, 2011, 528, p 3823-3828.

    Article  Google Scholar 

  12. U. Trdan, M. Skarba, J.A. Porro, J.L. Ocaña and J. Grum, Application of Massive Laser Shock Processing for Improvement of Mechanical and Tribological Properties, Surf. Coat. Technol., 2018, 342, p 1-11.

    Article  CAS  Google Scholar 

  13. Y. Li and Y. Shi, Microhardness, Wear Resistance, and Corrosion Resistance of AlxCrFeCoNiCu High-Entropy Alloy Coatings on Aluminum by Laser Cladding, Opt. Laser Technol., 2021, 134, p 106632.

    Article  CAS  Google Scholar 

  14. Y. Li, Shi Y, Phase Assemblage and Wear Resistance of Laser-Cladding Al0.8FeCoNiCrCu0.5 Six High-Entropy Alloys on Aluminum, Mater. Res. Exp., 2020, 7, p 086504.

    Article  CAS  Google Scholar 

  15. M.I. Bashir, M. Shafiq, M. Naeem, M. Zaka-ul-Islam, J.C. Díaz-Guillén, C.M. Lopez-Badillo and M. Zakaullah, Enhanced Surface Properties of Aluminum by PVD-TiN Coating Combined with Cathodic Cage Plasma Nitriding, Surf. Coat. Technol., 2017, 327, p 59-65.

    Article  CAS  Google Scholar 

  16. C. Lu, J.W. Yao, Y.X. Wang, Y.D. Zhu, J.H. Guo, Y. Wang, H.Y. Fu, Z.B. Chen and M.F. Yan, A Novel Anti-Frictional Multiphase Layer Produced by Plasma Nitriding of PVD Titanium Coated ZL205A Aluminum Alloy, Appl. Surf. Sci., 2018, 431, p 32-38.

    Article  CAS  Google Scholar 

  17. S. Brossard, P.R. Munroe and M.M. Hyland, Microstructural Study of Splat Formation for HVOF Sprayed NiCr On Pre-Treated Aluminum Substrates, J. Therm. Spray Technol., 2010, 19, p 1001-1012.

    Article  CAS  Google Scholar 

  18. E.S. Puchi-Cabrera, M.H. Staia, Y.Y. Santana, E.J. Mora-Zorrilla, J. Lesage, D. Chicot, J.G. La Barbera-Sosa, E. Ochoa-Perez and C.J. Villalobos-Gutierrez, Fatigue Behavior of AA7075-T6 Aluminum Alloy Coated with a WC–10Co–4Cr Cermet by HVOF Thermal Spray, Surf. Coat. Technol., 2013, 220, p 122-130.

    Article  CAS  Google Scholar 

  19. L. He, Y. Tan, X. Wang, T. Xu and X. Hong, Microstructure and Wear Properties of Al2O3-CeO2/Ni-Base Alloy Composite Coatings on Aluminum Alloys by Plasma Spray, Appl. Surf. Sci., 2014, 314, p 760-767.

    Article  CAS  Google Scholar 

  20. F. Fanicchia, X. Maeder, J. Ast, A.A. Taylor, Y. Guo, M.N. Polyakov, J. Michler and D.A. Axinte, Residual Stress and Adhesion of Thermal Spray Coatings: Microscopic View by Solidification and Crystallisation Analysis in the Epitaxial CoNiCrAlY Single Splat, Mater. Des., 2018, 153, p 36-46.

    Article  CAS  Google Scholar 

  21. A.A. Abubakar, A.F.M. Arif, K.S. Al-Athel, S.S. Akhtar and J. Mostaghimi, Modeling Residual Stress Development in Thermal Spray Coatings: Current Status and Way Forward, J. Therm. Spray Technol., 2017, 26, p 1115-1145.

    Article  Google Scholar 

  22. Y.Z. **ng, Z. Liu, G. Wang, X.H. Li, C.P. Jiang, Y.N. Chen, Y. Zhang, X.D. Song and M. Dargusch, Improvement of Interfacial Bonding between Plasma-Sprayed Cast Iron Splat and Aluminum Substrate Through Preheating Substrate, Surf. Coat. Technol., 2017, 316, p 190-198.

    Article  CAS  Google Scholar 

  23. W. Sun, X. Chu, H. Lan, R.Z. Huang, J.B. Huang, Y.C. **e, J. Huang, G. Huang, Current Implementation Status of Cold Spray Technology: A Short Review, J. Therm. Spray Technol., 2022, 31, p 848–865.

    Article  Google Scholar 

  24. S. Yin, M. Meyer, W. Li, H. Liao and R. Lupoi, Gas Flow, Particle Acceleration, and Heat Transfer in Cold Spray: A Review, J. Therm. Spray Technol., 2016, 25, p 874-896.

    Article  Google Scholar 

  25. M.R. Rokni, S.R. Nutt, C.A. Widener, V.K. Champagne and R.H. Hrabe, Review of Relationship between Particle Deformation, Coating Microstructure, and Properties in High-Pressure Cold Spray, J. Therm. Spray Technol., 2017, 26, p 1308-1355.

    Article  Google Scholar 

  26. H. Assadi, H. Kreye, F. Gärtner and T. Klassen, Cold Spraying–A Materials Perspective, Acta Mater., 2016, 116, p 382-407.

    Article  CAS  Google Scholar 

  27. X. Wang, L. Zhang, X. Zhou, W. Wu and X. Jie, Corrosion Behavior of Al2O3-Reinforced Graphene Encapsulated Al Composite Coating Fabricated by Low Pressure Cold Spraying, Surf. Coat. Technol., 2020, 386, p 125486.

    Article  CAS  Google Scholar 

  28. G. Huang, H. Wang, X. Li, L. **ng and J. Zhou, Deposition Efficiency of Low Pressure Cold Sprayed Aluminum Coating, Mater. Manuf. Process., 2018, 33, p 1100-1106.

    Article  CAS  Google Scholar 

  29. Q. Chen, M. Yu, K. Cao, H. Chen, Thermal Conductivity and Wear Resistance of Cold Sprayed Cuceramic Phase Composite Coating. Surf. Coat. Technol. 434 128135 (2022)

  30. N. Deng, J.R. Tang, T.Y. **ong, J.Q. Li and Z.J. Zhou, Fabrication and Characterization of WCu Composite Coatings with Different W Contents by Cold Spraying, Surf. Coat. Technol., 2019, 368, p 8-14.

    Article  CAS  Google Scholar 

  31. Y. Wang, Y.Q. Zhu, R.T. Li, H.T. Wang, L.H. Tian and H. Li, Microstructure and Wear Behavior of Cold-Sprayed Cu-BNNSs Composite Coating, J. Therm. Spray Technol., 2021, 30, p 1482-1492.

    Article  CAS  Google Scholar 

  32. R.H. Cheng, X.T. Luo, G.S. Huang and C.J. Li, Corrosion and Wear Resistant WC17Co-TC4 Composite Coatings with Fully Dense Microstructure Enabled by In-Situ Forging of the Large-Sized WC17Co Particles in Cold Spray, J. Mater. Process. Tech., 2021, 296, p 117231.

    Article  CAS  Google Scholar 

  33. S.A. Alidokht and R.R. Chromik, Sliding Wear Behavior of Cold-Sprayed Ni-WC Composite Coatings: Influence OF WC Content, Wear, 2021, 477, p 203792.

    Article  CAS  Google Scholar 

  34. L. He and M. Hassani, A Review of the Mechanical and Tribological Behavior of Cold Spray Metal Matrix Composites, J. Therm. Spray Technol., 2020, 29, p 1565-1608.

    Article  CAS  Google Scholar 

  35. D. Cong, Z. Li, Q. He, H. Chen, Z. Zhao, L. Zhang and H. Wu, Wear Behavior of Corroded Al-Al2O3 Composite Coatings Prepared by Cold Spray, Surf. Coat. Technol., 2017, 326, p 247-254.

    Article  CAS  Google Scholar 

  36. J.M. Shockley, S. Descartes, E. Irissou, J.G. Legoux and R.R. Chromik, Third Body Behavior During Dry Sliding of Cold-Sprayed Al-Al2O3 Composites: In situ Tribometry and Microanalysis, Tribol. Lett., 2014, 54, p 191-206.

    Article  Google Scholar 

  37. J.M. Shockley, S. Descartes, P. Vo, E. Irissou and R.R. Chromik, The Influence of Al2O3 Particle Morphology on the Coating Formation and Dry Sliding Wear Behavior of Cold Sprayed Al–Al2O3 Composites, Surf. Coat. Technol., 2015, 270, p 324-333.

    Article  CAS  Google Scholar 

  38. M. Yandouzi, A.J. Böttger, R.W.A. Hendrikx, M. Brochu, P. Richer, A. Charest and B. Jodoin, Microstructure and Mechanical Properties of B4C Reinforced Al-Based Matrix Composite Coatings Deposited by CGDS and PGDS Processes, Surf. Coat. Technol., 2010, 205, p 2234-2246.

    Article  CAS  Google Scholar 

  39. M. Yu and J. Hua, Effect of SiC Particle Size on the Microstructure and Properties of Cold-Sprayed Al/SiCp Composite Coating, Int. J. Mod. Phys. B, 2017, 31, p 1744027.

    Article  CAS  Google Scholar 

  40. S. Kumar, S.K. Reddy and S.V. Joshi, Microstructure and Performance of Cold Sprayed Al-SiC Composite Coatings with High Fraction of Particulates, Surf. Coat. Technol., 2017, 318, p 62-71.

    Article  CAS  Google Scholar 

  41. C. Huang, W.Y. Li, Z. Zhang, M. Fu, M.P. Planche, H.L. Liao and G. Montavon, Modification of a Cold Sprayed SiCp/Al5056 Composite Coating by Friction Stir Processing, Surf. Coat. Technol., 2016, 296, p 69-75.

    Article  CAS  Google Scholar 

  42. M. Yu, W.Y. Li, X.K. Suo and H.L. Liao, Effects of Gas Temperature and Ceramic Particle Content on Microstructure and Microhardness of Cold Sprayed SiCp/Al 5056 Composite Coatings, Surf. Coat. Technol., 2013, 220, p 102-106.

    Article  CAS  Google Scholar 

  43. K.S. Al-Hamdani, J.W. Murray, T. Hussain and A.T. Clare, Heat-Treatment and Mechanical Properties of Cold-Sprayed High Strength Al Alloys from Satellited Feedstocks, Surf. Coat. Technol., 2019, 374, p 21-31.

    Article  CAS  Google Scholar 

  44. K. Yang, W. Li, C. Huang, X. Yang and Y. Xu, Optimization of Cold-Sprayed AA2024/Al2O3 Metal Matrix Composites via Friction Stir Processing: Effect of Rotation Speeds, J. Mater. Sci. Technol., 2018, 34, p 2167-2177.

    Article  CAS  Google Scholar 

  45. X.B. Wang, The Metallurgical Behavior of B4C in the Iron-Based Surfacing Alloy During PTA Powder Surfacing, Appl. Surf. Sci., 2005, 252, p 2021-2028.

    Article  CAS  Google Scholar 

  46. M. Kirchgaßner, E. Badisch and F. Franek, Behaviour of Iron-Based Hardfacing Alloys Under Abrasion and Impact, Wear, 2008, 265, p 772-779.

    Article  Google Scholar 

  47. H. Durmuş, N. Çömez, C. Gül, M. Yurddaşkal and M. Yurddaşkal, Wear Performance of Fe-Cr-CB Hardfacing Coatings: Dry Sand/Rubber Wheel Test and Ball-On-Disc Test, Int. J. Refract. Met. H., 2018, 77, p 37-43.

    Article  Google Scholar 

  48. J. Gou, Y. Wang, Z. Sun and X. Li, Study of Work Function and Dry Sliding Wear Behavior of Fe-Based Hardfacing Alloys with and Without Nano Rare Earth Oxides, J. Alloy. Compd., 2017, 713, p 255-265.

    Article  CAS  Google Scholar 

  49. C.C. Sun, X.L. Zhou, J. Lu, L. **e, R.Z. Li, Y.D. Wu, X.D. Dan, M.N. Zhang, Formation of Al-based Metallic Glasses Composites Prepared by Cold Spraying. J. Therm. Spray Technol., 2022, 31, p 1844–1859.

    Article  CAS  Google Scholar 

  50. P. Liebersbach, A. Foelsche, V.K. Champagne, M. Siopis, A. Nardi and D.P. Schmidt, CFD Simulations of Feeder Tube Pressure Oscillations and Prediction of Clogging in Cold Spray Nozzles, J. Therm. Spray Technol., 2020, 29, p 400-412.

    Article  CAS  Google Scholar 

  51. Y.K. Wei, X.T. Luo, X. Chu, G.S. Huang and C.J. Li, Solid-State Additive Manufacturing High Performance Aluminum Alloy 6061 Enabled by an In-Situ Micro-Forging Assisted Cold Spray, Mater. Sci. Eng. A, 2020, 776, p 139024.

    Article  CAS  Google Scholar 

  52. X. Qiu, L. Qi, J.R. Tang, X.Y. Cui, H. Du, J.Q. Wang and T.Y. **ong, Influence of Particulate Morphology on Microstructure and Tribological Properties of Cold Sprayed A380/Al2O3 Composite Coatings, J. Mater. Sci. Technol., 2020, 44, p 9-18.

    Article  CAS  Google Scholar 

  53. W.Y. Li, G. Zhang, H.L. Liao and C. Coddet, Characterizations of Cold Sprayed TiN Particle Reinforced Al2319 Composite Coating, J. Mater. Process. Tech., 2008, 202, p 508-513.

    Article  CAS  Google Scholar 

  54. W.Y. Li, G. Zhang, C. Zhang, O. Elkedim, H.L. Liao and C. Coddet, Effect of Ball Milling of Feedstock Powder on Microstructure and Properties of TiN Particle-Reinforced Al Alloy-Based Composites Fabricated by Cold Spraying, J. Therm. Spray Technol., 2008, 17, p 316-322.

    Article  CAS  Google Scholar 

Download references

Acknowledgments

This work was funded by the Jihua Laboratory (X190391TJ190 and X201261XJ200) and National Key Research and Development Program (No. 2021YFB3702000). The author also would like to thank Yue Zhang since the marriage.

Author information

Authors and Affiliations

  1. Functional Coating and Remanufacturing Technology Research Center, Jihua Laboratory, Foshan, 528200, Guangdong Province, People’s Republic of China

    Chengchuan Sun, **g Lu, Dong Chen, Yingdong Wu & Ting Li

Authors
  1. Chengchuan Sun
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. **g Lu
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Dong Chen
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Yingdong Wu
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Ting Li
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to **g Lu.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Sun, C., Lu, J., Chen, D. et al. Iron-based Surfacing Alloy Composite Coatings Deposited on Al7075 Substrate Using Cold Spraying and Its Properties. J Therm Spray Tech 32, 1002–1017 (2023). https://doi.org/10.1007/s11666-022-01485-y

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11666-022-01485-y

Keywords

Search

Navigation