Cold Spraying of IN 718-Ni Composite Coatings: Microstructure Characterization and Tribological Performance

Abstract:

INCONEL 718 superalloy (IN 718) is frequently used in highly aggressive environments, such as aerospace and gas turbine engines, where excellent mechanical properties, creep-, fatigue- and oxidation-resistance performance at high and cryogenic temperatures are required. Recent studies have successfully cold sprayed IN 718, showing great potential mainly in maintenance and repairing fields. However, due to the low plastic deformation, the manufacture of IN 718 cold sprayed coatings often requires the use of expensive propulsive gases or high working parameters to enhance deposition efficiency, with a significant increase in production costs. This paper investigates for the first time the addition of Ni to IN 718 powders in order to increase plastic deformation and interparticle bonding strength. Four composite coatings were deposited via a high-pressure cold spray process using nitrogen as propulsive gas, considering different IN 718 mass fractions in the feedstock: C1 (0 wt%), C2 (25 wt%), C3 (50 wt%), C4 (75 wt%). The coatings are examined in terms of microstructural characteristics and tribological performance. The addition of IN 718 particles significantly improves the mechanical properties of the coatings, despite an increase in porosity, which however does not exceed 1%. The tribological performance of the four coatings is investigated using a pin-on-disk test, demonstrating that the coating wear resistance behaviour improved as the IN 718 content increased. Analysis of the wear mechanism shows that C4 coating has a different wear behaviour than the other coatings, thus achieving the best wear-resistance performance.

• Periodical: Materials Science Forum (Volume 1016)
• Pages: 840-845
• DOI: https://doi.org/10.4028/www.scientific.net/MSF.1016.840
• Online since: January 2021
• Authors: Roberto Biagi, Elisa Verna, Marios Kazasidis, Edoardo Bemborad, Maurizio Galetto, Shuo Yin, Rocco Lupoi*
• Keywords: Cold Spray, Inconel 718, Nickel, Pin-on-Disk Test, Tribology

References

[1] G.E. Totten ASM Handbook, Volume 18: Friction, Lubrication, and Wear Technology, (Materials Park, OH), ASM international (1992).

[2] H. Singh, T.S. Sidhu, and S.B.S. Kalsi Cold Spray Technology: Future of Coating Deposition Processes Frat. ed Integrità Strutt. (2012) 6(22) 69–84.

DOI: 10.3221/igf-esis.22.08

[3] C. Chen, Y. Xie, X. Xie, X. Yan, R. Huang, J. Wang, Z. Ren, S. Deng, and H. Liao Effects of Substrate Heat Accumulation on the Cold Sprayed Ni Coating Quality: Microstructure Evolution and Tribological Performance Surf. Coatings Technol. Elsevier (2019).

DOI: 10.1016/j.surfcoat.2019.04.090

[4] S. Yin, E.J. Ekoi, T.L. Lupton, D.P. Dowling, and R. Lupoi Cold Spraying of WC-Co-Ni Coatings Using Porous WC-17Co Powders: Formation Mechanism, Microstructure Characterization and Tribological Performance Mater. Des. Elsevier (2017) 126 305–313.

DOI: 10.1016/j.matdes.2017.04.040

[5] H. Qi, M. Azer, and A. Ritter Studies of Standard Heat Treatment Effects on Microstructure and Mechanical Properties of Laser Net Shape Manufactured Inconel 718 Metall. Mater. Trans. A Springer (2009) 40(10) 2410–2422.

DOI: 10.1007/s11661-009-9949-3

[6] E. Verna, R. Biagi, M. Kazasidis, M. Galetto, E. Bemporad, and R. Lupoi Modeling of Erosion Response of Cold-Sprayed In718-Ni Composite Coating Using Full Factorial Design Coatings Multidisciplinary Digital Publishing Institute (2020) 10(4) 335.

DOI: 10.3390/coatings10040335

[7] T. Marrocco, D. McCartney, P. Shipway, and A.J. Sturgeon Comparison of the Microstructure of Cold Sprayed and Thermally Sprayed IN718 Coatings, Thermal Spray 2006: Building on 100 Years of Success B. Marple, M. Hyland, Y.-C. Lau, R.S. Lima, and J. Voyer, Eds. (Materials Park, OH), ASM International (2006) 15–18.

DOI: 10.31399/asm.cp.itsc2006p0265

[8] W. Wong, E. Irissou, P. Vo, M. Sone, F. Bernier, J.-G. Legoux, H. Fukanuma, and S. Yue Cold Spray Forming of Inconel 718 J. Therm. spray Technol. Springer (2013) 22(2–3) 413–421.

DOI: 10.1007/s11666-012-9827-1

[9] W. Sun, A. Bhowmik, A.W.Y. Tan, F. Xue, I. Marinescu, F. Li, and E. Liu Strategy of Incorporating Ni-Based Braze Alloy in Cold Sprayed Inconel 718 Coating Surf. Coatings Technol. Elsevier (2019) 358 1006–1012.

DOI: 10.1016/j.surfcoat.2018.12.050

[10] A. Chaudhuri, Y. Raghupathy, D. Srinivasan, S. Suwas, and C. Srivastava Microstructural Evolution of Cold-Sprayed Inconel 625 Superalloy Coatings on Low Alloy Steel Substrate Acta Mater. Elsevier (2017) 129 11–25.

DOI: 10.1016/j.actamat.2017.02.070

[11] C. Stenson, K.A. McDonnell, S. Yin, B. Aldwell, M. Meyer, D.P. Dowling, and R. Lupoi Cold Spray Deposition to Prevent Fouling of Polymer Surfaces Surf. Eng. Taylor & Francis (2018) 34(3) 193–204.

DOI: 10.1080/02670844.2016.1229833

[12] ASTM G99-17 Standard Test Method for Wear Testing with a Pin-on-Disk Apparatus, (West Conshohocken, PA), ASTM International (2017).

[13] K. Zhuang, D. Zhu, X. Zhang, and H. Ding Notch Wear Prediction Model in Turning of Inconel 718 with Ceramic Tools Considering the Influence of Work Hardened Layer Wear Elsevier (2014) 313(1–2) 63–74.

DOI: 10.1016/j.wear.2014.02.007

[14] N. Cinca and J.M. Guilemany Cold Gas Sprayed Stellite-6 Coatings Andtheir Wear Resistance J Mater. Sci Eng (2013) 2(122) 22–2169.