Pore Feature and Cracking Behavior of Cold-sprayed Al-based Composite Coatings under Reciprocating Friction

doi:10.11901/1005.3093.2023.409

Chinese Journal of Materials Research

2024, Vol. 38

Issue (7): 481-489 DOI: 10.11901/1005.3093.2023.409

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Pore Feature and Cracking Behavior of Cold-sprayed Al-based Composite Coatings under Reciprocating Friction

WANG Jinlong¹, WANG Huiming¹, LI Yingju², ZHANG Hongyi³, LV Xiaoren¹(

)

^1.College of Mechanical Engineering, Shenyang University of Technology, Shenyang 110870, China
^2.Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China
^3.Shenyang Aerospace Mitsubishi Motors Automobile Engine Manufacturing Co., Ltd., Shenyang 110179, China

Cite this article:

WANG Jinlong, WANG Huiming, LI Yingju, ZHANG Hongyi, LV Xiaoren. Pore Feature and Cracking Behavior of Cold-sprayed Al-based Composite Coatings under Reciprocating Friction. Chinese Journal of Materials Research, 2024, 38(7): 481-489.

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Abstract

Al-based composite coatings containing 30%Al₂O₃ were prepared on AZ31 Mg-alloy via cold-spraying technique. Then the pore feature and cracking behavior of Al-based composite coatings during reciprocating friction testing was assessed by means of a wear-testing machine, as well as and the location of crack initiation for relevant pores on the cross section of coatings. Meanwhile, models for composite coatings of elliptical-, triangular-, and rectangular-pores, and pore-free were respectively established using Abaqus and Python scripts, then the maximum stress of pores during friction and the residual stress on the top surface after friction were analyzed for the composite coatings. The relationship between stress finite element results and the size of cracks induced by reciprocating friction was discussed. The research findings indicated that stress concentration for elliptical-, triangular-, and rectangular-pores mainly occurred at the endpoints of the major axis or at their corners during friction. From the top surface to the interface, the residual stress transformed from tensile stress to compressive stress and then back to tensile stress. For elliptical-, triangular-, and rectangular-pores, the maximum Mises stress and average residual stress on the surface gradually increased. Cracks initiated and propagated from the endpoints of the major axis for elliptical pores, while cracks in triangular- and rectangular-pores originated from the corners, with corresponding increases in crack length and width. Finite element analysis revealed that the increase in the maximum Mises stress of poresduring friction led to an increase in the average residual stress on the surface after friction. This, in turn, resulted in larger crack dimensions, consistent with the findings from the reciprocating friction experiments.

Key words: metallic materials magnesium alloy cold spray stress concentration pore morphology

Received: 20 August 2023

ZTFLH:

TH117

Fund: National Defense Science and Technology Key Laboratory Fund(JCKY61420052021)

Corresponding Authors: LV Xiaoren, Tel: 13504077230, E-mail: xrlvsut@126.com

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	WANG Jinlong
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https://www.cjmr.org/EN/10.11901/1005.3093.2023.409 OR https://www.cjmr.org/EN/Y2024/V38/I7/481

Table 1 Chemical composition of AZ31 magnesium alloy (mass fraction, %)

Fig.1 SEM morphology of Al powder (a) and Al₂O₃ powder (b)

Fig.2 Particle size distribution of pure Al and Al₂O₃ powder

Table 2 Processing parameters of cold spray

Fig.3 Metallographic photo of coating

Fig.4 Electron micrographs of coatings and pores of different shapes (a) coating; (b) elliptical pores; (c) triangular pores; (d) rectangular pores

Fig.5 Composite coating models with different pore shapes (a) elliptical pores; (b) triangular pores; (c) rectangular pores; (d) no pores

Fig.6 Model meshes of composite coatings with different pore shapes (a) elliptical pores; (b) triangular pores; (c) rectangular pores; (d) no pores

Fig.7 Friction diagram

Fig.8 Frictional Mises stress cloud diagram of cold spray coating (a) elliptical pores; (b) triangular pores; (c) rectangular pores; (d) no pores

Table 3 Mises stress of pores with different shapes in process of friction

Fig.9 Friction S11 and S22 stress cloud diagrams of cold sprayed coatings (a, e) elliptical pores; (b, f) triangular pores; (c, g) rectangular pores; (d, h) no pores

Fig.10 Average stress of the surface elements S11 and S22 for pores with different shapes in process of friction

Fig.11 SEM images of coatings and pores of different shapes after reciprocating friction (a) coating; (b) rectangle; (c) triangle; (d) ellipse

Fig.12 Crack length and width of pores with different shapes

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