Influence of inter-splat bonding state of cold sprayed IN625 and IN718 coatings on mechanical and corrosion performance

• Published in: Surface & coatings technology Vol. 445; p. 128731
• Main Authors: Devi, G. Neelima, Kumar, S., Balaji, T. Sharanya, Mangalarapu, Tarun Babu, Chandrasekhar, S.B., Gopal, A. Venu, Jyothirmayi, A.
• Format: Journal Article
• Language: English
• Published: Elsevier B.V 15-09-2022
• Subjects: Cold spray; Corrosion; Finite element modelling; Inconel; Splat; Finite element modelling; Corrosion; Splat; Cold spray; Inconel
• ISSN: 0257-8972; 1879-3347
• DOI: 10.1016/j.surfcoat.2022.128731

Component reclamation and additive manufacturing using cold spray technique is gaining attention in various industrial sectors as one of the cheapest alternative. Depositing super alloys (IN625 and IN718) using air as a process gas (As against Nitrogen or Helium) further reduces the deposition cost. In this work, inter-splat bonding states at the impacting interfaces of IN625 and IN718 in cold spraying are studied through Finite Element Modelling (FEM) studies and the bonding fraction is correlated with the microstructure, and performance of the coatings. The role of process temperature along with the impact velocity of the powder particle is considered rather than impact velocity alone to estimate the bonding state. This synergistic effect upon impact paves a way to successfully deposit high temperature structural materials such as Inconel using air as a process gas. The inter-splat bonding state for the coatings deposited at different process conditions, correlates well with the mechanical and corrosion performance of the coatings.
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•Cold spray deposition of IN625 and IN718 were demonstrated using air as process gas.•Inter-splat bonding is thoroughly studied and correlated with the functionality.•Influence of spray condition on the properties upon heat treatment is studied.