Abstract
Low-pressure cold spraying was used to deposit A5052 and Al coatings on structural Q355B steel to improve its fatigue performance. Through the experiments and finite-element simulation, the fatigue crack growth behavior of Q355B steel substrate after polishing, grit blasting, and cold spraying with A5052 and Al powders were compared and analyzed. The bonding strengths of coatings to the substrate surfaces were measured through tensile testing. Three-point bending testing, with fracture morphology analysis and extended finite-element simulation, was conducted to analyze the effects of cold spraying coatings on the crack growth of Q355B steel. Results showed that the effects of grit blasting and cold spraying with A5052 and Al powders, and their combined effect, were conducive to the enhanced fatigue performance of Q355B steel.
Get full access to this article
View all available purchase options and get full access to this article.
Data Availability Statement
No data, models, or code were generated or used during the study.
Acknowledgments
This work was supported by the Natural Science Foundation of China (No. 51801143), the Natural Science Foundation of Shaanxi (No. 2018JZ5015), the Shaanxi Ministry of Education (No. 17JS064), and the Science and Technology Foundation of Xi’an University of Architecture and Technology (2019) (No. ZR19012). The authors acknowledge the Shaanxi Provincial Key Laboratory of Environmental and Municipal Engineering, the Shaanxi Key Laboratory of Surface Engineering and Remanufacturing, and the Mechanics Laboratory of the College of Science, Xi’an University of Architecture and Technology, for providing test equipment and conditions.
References
Assadi, H., T. Schmidt, H. Richter, J. O. Kliemann, K. Binder, F. Gartner, T. Klassen, and H. Kreye. 2011. “On parameter selection in cold spraying.” J. Therm. Spray Technol. 20 (6): 1161–1176. https://doi.org/10.1007/s11666-011-9662-9.
Ayatollahi, M. R., S. M. J. Razavi, C. Sommitsch, and C. Moser. 2016. “Fatigue life extension by crack repair using double stop-hole technique.” Trans. Tech. Publ. 879: 3–8. https://doi.org/10.4028/www.scientific.net/MSF.879.3.
Belytschko, T., and T. Black. 1999. “Elastic crack growth in finite elements with minimal remeshing.” Int. J. Numer. Methods Eng. 45 (5): 601–620. https://doi.org/10.1002/(SICI)1097-0207(19990620)45:5%3C601::AID-NME598%3E3.0.CO;2-S.
Champagne, V. K. 2007. The cold spray materials deposition process: Fundamentals and applications. Cambridge, MA: Woodhead.
Chen, T. L., Z. Li, N. X. Zhang, X. B. Song, and Y. Y. Hidekuma. 2018. “Fatigue performance test on inclined central cracked steel plates repaired with CFRP strand sheets.” Thin Walled Struct. 130 (Sep): 414–423. https://doi.org/10.1016/j.tws.2018.06.004.
Chen, W. J., H. Chen, C. Li, C. X. L. Wang, and Q. Cai. 2017. “Microstructure and fatigue crack growth of EA4T steel in laser cladding remanufacturing.” Eng. Fail. Anal. 79 (Sep): 120–129. https://doi.org/10.1016/j.engfailanal.2017.03.005.
Chinese Standards. 1999. Sample location and preparation of mechanical properties of steel and steel products. [In Chinese.] GB/T 2975-1998. Beijing: China Standards Press.
Chinese Standards. 2010. Metallic materials tensile testing at ambient temperature. Part One: Ambient temperature test method. [In Chinese.] GB/T 228.1. Beijing: China Standards Press.
Civil Aviation Administration of China. 2013. Test method for adhesion or cohesion strength of thermal spray coatings. [In Chinese.]. Beijing: Civil Aviation Administration of China.
Dassault Systémes. 2015. Abaqus keyword reference guide. [In Chinese.] Nanjing, China: Southeast University Press.
Dassault Systémes. 2016. Abaqus Analysis User’s Manual: Part III: Analysis procedures, solution, and control. 11.4.3 Crack propagation analysis. Vélizy-Villacoublay, France: Dassault Systémes.
Dayani, S. B., S. K. Shaha, R. Ghelichi, J. F. Wangc, and H. Jaheda. 2018. “The impact of AA7075 cold spray coating on the fatigue life of AZ31B cast alloy.” Surf. Coat. Tech. 337 (Mar): 150–158. https://doi.org/10.1016/j.surfcoat.2018.01.008.
Dykhuisen, R., and M. Smith. 1998. “Gas dynamic principle of cold spray.” J. Therm. Spray Technol. 7 (2): 205–212. https://doi.org/10.1361/105996398770350945.
Dykhuisen, R., M. F. Smith, and D. L. Gilmore. 1999. “Impact of high velocity cold spray particles.” J. Therm. Spray Technol. 8 (4): 559–564. https://doi.org/10.1361/105996399770350250.
Gartner, F., T. Schmidt, and H. Kreye. 2007. “Present status and future prospects of cold spraying.” Mater. Sci. Forum 534–536: 433–436.
Ghelichi, R., S. Bagherifard, D. M. Donald, M. Brochu, H. Jahed, B. Jodoin, and M. Guagliano. 2014b. “Fatigue strength of Al alloy cold sprayed with nanocrystalline powders.” Int. J. Fatigue 65 (Aug): 51–57. https://doi.org/10.1016/j.ijfatigue.2013.09.001.
Ghelichi, R., S. Bagherifard, D. Macdonald, I. Fernandez-Pariente, B. Jodoin, and M. Guagliano. 2014a. “Experimental and numerical study of residual stress evolution in cold spray coating.” Appl. Surf. Sci. 288 (Jan): 26–33. https://doi.org/10.1016/j.apsusc.2013.09.074.
Grujicic, M., C. L. Zhao, W. S. DeRosset, and D. Helfricht. 2004a. “Adiabatic shear instability based mechanism for particles/substrate bonding in the cold-gas dynamic-spray process.” Mater. Des. 25 (8): 681–688. https://doi.org/10.1016/j.matdes.2004.03.008.
Grujicic, M., C. L. Zhao, C. Tong, W. S. DeRosset, and D. Helfricht. 2004b. “Analysis of the impact velocity of powder particles in the cold-gas dynamic-spray process.” Mater. Sci. Eng. A 368 (1–2): 222–230. https://doi.org/10.1016/j.msea.2003.10.312.
Hussain, T., D. G. McCartney, P. H. Shipway, and D. J. Zhang. 2009. “Bonding mechanisms in cold spraying: The contributions of metallurgical and mechanical components.” J. Therm. Spray Technol. 18 (3): 364–379. https://doi.org/10.1007/s11666-009-9298-1.
ISO. 2018. Metallic materials—Fatigue testing—Fatigue crack propagation method. ISO 12108. Geneva: ISO.
Kashaev, N., V. Ventzke, and M. Horstmann. 2017. “Effects of laser shock peening on the microstructure and fatigue crack propagation behaviour of thin AA2024 specimens.” Int. J. Fatigue 98 (May): 223–233. https://doi.org/10.1016/j.ijfatigue.2017.01.042.
Kosarev, V. K., S. V. Klinkov, A. P. Alkhimov, and A. Papyrin. 2003. “On some aspects of gas dynamics of the cold spray process.” J. Therm. Spray Technol. 12 (2): 265–281. https://doi.org/10.1361/105996303770348384.
Kumar, S., G. Bae, and C. Lee. 2009. “Deposition characteristics of copper particles on roughened substrates through kinetic spraying.” Appl. Surf. Sci. 255 (6): 3472–3479. https://doi.org/10.1016/j.apsusc.2008.10.060.
Marrocco, T., D. G. McCartney, P. H. Shipway, and A. J. Sturgeon. 2006. “Production of titanium deposits by cold-gas dynamic spray: Numerical modeling and experimental characterization.” J. Therm. Spray Technol. 15 (2): 263–272. https://doi.org/10.1361/105996306X108219.
Moës, N., J. Dolbow, and T. Belytschko. 1999. “A finite element method for crack growth without remeshing.” Int. J. Numer. Methods Eng. 46 (1): 131–150. https://doi.org/10.1002/(SICI)1097-0207(19990910)46:1%3C131::AID-NME726%3E3.0.CO;2-J.
Papyrin, A., V. Kosarev, K. V. Klinkov, A. Alkhimov, and V. K. Fomin. 2006. Cold spray technology. Oxford, UK: Elsevier.
Paris, P., and F. Erdogan. 1963. “A critical analysis of crack propagation laws.” J. Basic Eng. 85 (4): 528–533. https://doi.org/10.1115/1.3656900.
Price, T. S., P. H. Shipway, and D. G. Mccartney. 2006. “Effect of cold spray deposition of a titanium coating on fatigue behavior of a titanium alloy.” J. Therm. Spray Technol. 15 (4): 507–512. https://doi.org/10.1361/105996306X147108.
Richer, P., B. Jodoin, L. Ajdelsztajn, and E. J. Lavernia. 2009. “Substrate roughness and thickness effects on cold spray nanocrystalline Al–Mg coatings.” J. Therm. Spray Technol. 15 (2): 246–254. https://doi.org/10.1361/105996306X108174.
Sakaki, K., T. Tajima, H. Li, S. Shinkai, and Y. Shimizu. 2004. Thermal spray: Advances in technology and application, 358–362. Cleveland: ASM International.
Shin, C. S., C. M. Wang, and P. S. Song. 1996. “Fatigue damage repair: A comparison of some possible methods.” Int. J. Fatigue 18 (8): 535–546. https://doi.org/10.1016/S0142-1123(96)00029-1.
Singh, R., K. H. Rauwald, E. Wessel, G. Mauer, S. Schruefer, A. Barth, S. Wilson, and R. Vassen. 2017. “Effects of substrate roughness and spray-angle on deposition behavior of cold-sprayed Inconel 718.” Surf. Coat. Tech. 319 (Jun): 249–259. https://doi.org/10.1016/j.surfcoat.2017.03.072.
Song, B., M. Chen, and L. X. Chen. 2013. “The impact of sandblasting preprocessing on bonding strength of high velocity arc spraying coating.” [In Chinese.] Mach. Des. Res. 29 (3): 77–79.
Song, P. S., and Y. L. Shieh. 2004. “Stop drilling procedure for fatigue life improvement.” Int. J. Fatigue 26 (12): 1333–1339. https://doi.org/10.1016/j.ijfatigue.2004.04.009.
Stoltenhoff, T., C. Borchers, F. Gartner, and H. Kreye. 2006. “Microstructures and key properties of cold-sprayed and thermally sprayed copper coatings.” Surf. Coat. Technol. 200 (16–17): 4947–4960. https://doi.org/10.1016/j.surfcoat.2005.05.011.
Stoltenhoff, T., H. Kreye, and H. J. Richter. 2002. “An analysis of the cold spray process and its coatings.” J. Therm. Spray Technol. 11 (4): 542–550. https://doi.org/10.1361/105996302770348682.
Sun, W., A. W. Y. Tan, N. W. Khun, I. Marinescu, and E. Liu. 2017. “Effect of substrate surface condition on fatigue behavior of cold sprayed Ti6Al4V coatings.” Surf. Coat. Tech. 320 (Jun): 452–457. https://doi.org/10.1016/j.surfcoat.2016.11.093.
Sun, W., A. W. Y. Tan, A. Bhowmik, I. Marinescu, X. Song, W. Zhai, F. Li, and E. Liu. 2018. “Deposition characteristics of cold sprayed Inconel 718 particles on Inconel 718 substrates with different surface conditions.” Mater. Sci. Eng. A 720 (Mar): 75–84. https://doi.org/10.1016/j.msea.2018.02.059.
Walker, K. F., J. M. Lourenço, S. Sun, M. Brandt, and C. H. Wang. 2016. “Quantitative fractography and modelling of fatigue crack propagation in high strength AerMet®100 steel repaired with a laser cladding process.” Int. J. Fatigue 94 (Part 2): 288–301. https://doi.org/10.1016/j.ijfatigue.2016.06.031.
Wang, C. D., J. Z. Zhou, and S. Huang. 2011. “Study on the improvement of fatigue crack growth performance of 6061-T6 aluminum alloy subject to laser shot peenin.” Key Eng. Mater. 464: 391–394. https://doi.org/10.4028/www.scientific.net/KEM.464.391.
Wang, G., B. G. Zhang, and J. C. Feng. 2008. “Research progress in pepair welding technology of Ni-based superalloy blands.” [In Chinese.] Weiding Join. 1: 20–23.
White, B. C., W. A. Story, L. N. Brewer, and J. B. Jordon. 2018. “Fatigue behavior of freestanding AA2024 and AA7075 cold spray deposits.” Int. J. Fatigue 112 (1): 355–360. https://doi.org/10.1016/j.ijfatigue.2018.03.007.
Wu, J., J. Yang, H. Fang, S. Yoon, and C. Lee. 2006. “The bond strength of Al-Si coating on mild steel by kinetic spraying deposition.” Appl. Surf. Sci. 252 (22): 7809–7814. https://doi.org/10.1016/j.apsusc.2005.09.015.
Yang, J. F., J. L. Yang, K. Qu, Q. Wang, and J. Xie. 2019. “Improved fatigue crack propagation performance of Q355B steel with cold-sprayed A5052 and Al coatings.” Surf. Coat. Tech. 378 (Nov): 12500. https://doi.org/10.1016/j.surfcoat.2019.125000.
Yin, S., Y. C. Xie, X. K. Suo, H. L. Liao, and X. F. Wang. 2015. “Interfacial bonding features of Ni coating on Al substrate with different surface pretreatments in cold spray.” Mater. Lett. 138 (Jan): 143–147. https://doi.org/10.1016/j.matlet.2014.10.016.
Zeljko, D. 1996. “Comparison of fatigue crack retardation methods.” Eng. Fail. Anal. 3 (2): 137–147. https://doi.org/10.1016/1350-6307(96)00006-4.
Zhang, H. T., X. X. Xue, Y. Zheng, and P. Feng. 2010. “Using CFRP to repair the steel pipe with fatigue cracks.” Adv. Mater. Res. 146–147: 1086–1089. https://doi.org/10.4028/www.scientific.net/AMR.146-147.1086.
Ziemian, C. W., M. M. Sharma, B. D. Bouffard, T. Nissley, and T. J. Eden. 2014. “Effect of substrate surface roughening and cold spray coating on the fatigue life of AA2024 specimens.” Mater. Des. 54 (Feb): 212–221. https://doi.org/10.1016/j.matdes.2013.08.061.
Information & Authors
Information
Published In
Journal of Materials in Civil Engineering
Volume 32 • Issue 9 • September 2020
Copyright
©2020 American Society of Civil Engineers.
History
Received: Sep 25, 2019
Accepted: Feb 10, 2020
Published online: Jun 30, 2020
Published in print: Sep 1, 2020
Discussion open until: Nov 30, 2020
Authors
Metrics & Citations
Metrics
Citations
Download citation
If you have the appropriate software installed, you can download article citation data to the citation manager of your choice. Simply select your manager software from the list below and click Download.