scholarly journals Bonding Characteristics of Cold Sprayed Copper Coating on Alumina coated Q235 Steel Substrate

2021 ◽  
Author(s):  
Guosheng HUANG ◽  
Li MA ◽  
Lukuo XING ◽  
Xiangbo LI
Keyword(s):  
Steel Substrate ◽  
Pure Copper ◽  
Cold Spraying ◽  
Copper Coating ◽  
Alumina Layer ◽  
Al2o3 Layer ◽  
Cross Sectional ◽  
Bonding Quality ◽  
Q235 Steel ◽  
Copper Powders

Cold spraying metallic coatings on ceramics (Ceramics Metallizing) are widely concerned in electrical industry due to its high density, low oxidation and high electrical conductivity. However, the bonding reliability of cold spraying coating on ceramics is usually considered to be poor since the metal particles don’t experience melting. The present paper is to exam the bonding quality of a cold spraying copper coating on a thermal sprayed alumina layer influenced by ceramics roughness and copper particle hardness. Pure copper coatings were successfully deposited on Al2O3 coated Q235 steel substrate with different roughness by cold spraying at 260 ℃ and 1.6 MPa using different hardness pure copper powders. The bonding quality and characteristics were studied by analyzing the surface, the cross-sectional microstructure of the coating and its interface after pull-off test. The results indicate that the high bonding quality (ranging from 8.26 MPa to 11.35 MPa) between copper coating and Al2O3 layer attributes to both metallurgical and interlock effect, which is mainly influenced by the hardness of the copper powders instead of Al2O3 surface roughness. The soft character of the pure copper powder makes it ready for deformation, subsequently interlocks with Al2O3, fills into the pores more completely, which increases the bonding quality between the copper coating and the Al2O3 layer.

Diffusion Study of Al-8%Si Alloy Double-Coating on Steel

2011 ◽  
Vol 189-193 ◽  
pp. 1080-1084
Author(s):  
Yu Heng Lu ◽  
Cai Min Huang ◽  
Jian Min Zeng
Keyword(s):  
High Temperature ◽  
Steel Substrate ◽  
Compositional Analysis ◽  
Optical Microscope ◽  
Heat Diffusion ◽  
Cross Sectional ◽  
Temperature Oxidation ◽  
Q235 Steel ◽  
Diffusion Treatment ◽  
Double Coating

Al-8%Si alloy double-coating on Q235 steel were produced, Then the samples were executed diffusion at high temperatures protecting with flowing argon gas. Scanning electron microscope (SEM), optical microscope (OM), and energy dispersive X-ray spectroscope (EDS) were employed for microstructure observation of cross-sectional, surface and compositional analysis of coating. The diffusion mathematical model was established with the finite element method. The results show that good quality Al-8%Si coating is made; after heat-diffusion treatment, the new phases FeAl and Fe3Al presents; Silicon atoms in Al-8%Si alloy can hinder the diffusion of aluminum atoms into steel substrate at high temperature; Al-8%Si alloy double-coating sample’s high-temperature oxidation resistance is higher than Q235 steel. This material is hopefully used in the engine exhaust manifold.

scholarly journals Physical and Electrochemical Performances of Cold Sprayed Pb Electrodes

Coatings ◽  
2019 ◽  
Vol 9 (3) ◽  
pp. 174
Author(s):  
Guosheng Huang ◽  
Yaowei Zhuang ◽  
Wei Fu
Keyword(s):  
Electrode Materials ◽  
Steel Substrate ◽  
Cold Spraying ◽  
Sulfate Solution ◽  
Coated Sample ◽  
Electrochemical Performances ◽  
High Porosity ◽  
Cross Sectional ◽  
Pbo2 Electrode ◽  
Pbo2 Electrodes

Titanium-based PbO2 electrodes are widely used for chemical industries, such as electrodialysis, electrolysis, and electrodepositing, to improve the mechanical and life cycle properties of Pb metal electrodes. However, PbO2 electrodes are usually electrodeposited onto rigid metals due to its soft characteristic, which results in severe passivation problems requiring thin thickness and high porosity. It is of great importance to develop a rigid Pb metal electrode system since thermal spraying and welding methods fail to manufacture such a promising electrode. In the present work, the cold spraying method was used to deposit a pure Pb metal coating with thickness of above 500 μm on Q235 steel substrate. The coating has good physical performances, the porosity is less than 1%, and the bonding strength ranges from 6.25 to 7.75 MPa. The cross-sectional morphology suggests that no through-thickness pores exist in the coating. The oxygen evolution potential is larger than 1.5 V vs. SCE, which is similar to the potential of the titanium-based PbO2 electrode. Dynamic polarization curves and cyclic voltammetry curves of coated sample in sodium sulfate solution indicate that cold sprayed Pb coating is a good electrode for electrochemical reduction reactions. All our results mean that cold spraying is capable of manufacturing electrode materials for electrochemical industries.

Comparison of Focused Ion Beam and Conventional Techniques on Tem Specimen Preparation of Metal-Ceramic Interfaces

1998 ◽  
Vol 4 (S2) ◽  
pp. 860-861 ◽  
Author(s):  
A. Ramirez de Arellano López ◽  
W.-A. Chiou ◽  
K. T. Faber
Keyword(s):  
Focused Ion Beam ◽  
Ceramic Coating ◽  
Steel Substrate ◽  
Ion Beam ◽  
Specimen Preparation ◽  
Inhomogeneous Materials ◽  
Cross Sectional ◽  
Fine Grain ◽  
Basic Industry ◽  
Coated Surface

The results of TEM analyses of materials are critically dependent on the quality of the sample prepared. Although numerous techniques have been developed in the last two decades, differential thinning of inhomogeneous materials remains a serious problem. Recently, focused ion beam (FIB) technique has been introduced for cross-sectional sample preparation for TEM and SEM.A novel system for depositing a fine-grain (∼ 200 nm) ceramic coating on a metal surface via a patent pending Small-Particle Plasma Spray (SPPS) technique has been developed at the Basic Industry Research Laboratory of Northwestern University. To understand the properties of the coated surface, the ceramic/metal interface and the microstructure of the ceramic coating must be investigated. This paper presents a comparison of the microstructure of an A12O3 coating on a mild steel substrate prepared using conventional and FEB techniques.

scholarly journals Microstructural and Corrosion Behavior of High Velocity Arc Sprayed FeCrAl/Al Composite Coating on Q235 Steel Substrate

Coatings ◽  
2019 ◽  
Vol 9 (9) ◽  
pp. 542 ◽  
Author(s):  
Ndumia Joseph Ndiithi ◽  
Min Kang ◽  
Jiping Zhu ◽  
Jinran Lin ◽  
Samuel Mbugua Nyambura ◽  
...  
Keyword(s):  
Corrosion Resistance ◽  
Composite Coating ◽  
High Velocity ◽  
Steel Substrate ◽  
Arc Spraying ◽  
Spray Parameters ◽  
Q235 Steel ◽  
Electrochemical Tests ◽  
Al Composite ◽  
Al Coating

High velocity arc spraying was used to prepare FeCrAl/Al composite coating on Q235 steel substrate by simultaneously spraying FeCrAl wire as the anode and Al wire as the cathode. The composite coating was sprayed with varying voltage and current to obtain optimum coating characteristics. FeCrAl coating was also prepared for comparison purposes. The surface microstructure of the coatings was characterized by scanning electron microscope (SEM) and X-ray diffraction (XRD). The average microhardness of the coatings and the substrate was analyzed and compared. Corrosion resistance was investigated by means of electrochemical tests. The image results showed that a lamellar structure consisted of interwoven layers of FeCrAl and Al. Al and FeCr constituted the main phases with traces of oxides and AlFe intermetallic compounds. The average porosity was reduced and microhardness of the coatings was improved with increasing voltage and current. The FeCrAl/Al coating formed alternating layers of hard and ductile phases; the corrosion resistance of the coatings in the sodium chloride (NaCl) solution depended on the increase in Al content and spray parameters. The corrosion resistance tests indicated that FeCrAl/Al coating had a better corrosion resistance than the FeCrAl coating. FeCrAl/Al can be used to coat steel substrates and increase their corrosion resistance.

Experimental Investigation of Effective Thermal Conductivity for LHP Wicks

2010 ◽  
Author(s):  
Gongming Xin ◽  
Kehang Cui ◽  
Yan Chen ◽  
Wenjing Du ◽  
Yong Zou ◽  
...  
Keyword(s):  
Thermal Conductivity ◽  
Experimental Investigation ◽  
Effective Thermal Conductivity ◽  
Pure Copper ◽  
Pure Nickel ◽  
Loop Heat Pipe ◽  
Porosity Level ◽  
Nickel Powders ◽  
Copper Powders ◽  
Reasonable Prediction

In this study, the effective thermal conductivity (ETC) of sintered loop heat pipe wicks, with pure nickel powders, pure copper powders, Ni-10wt%Cu powders and Ni-20wt%Cu powders were experimentally investigated. The ETC of sintered Ni-Cu wicks is found less than those of sintered pure nickel wick and sintered pure copper wicks. In the same porosity level, addition of copper into nickel will reduce ETC of the sintered Ni-Cu wicks. The sintered Ni-20wt%Cu wick presents the lowest ETC among the tested wick samples. Compared to experimental results, Alexander model can provide a reasonable prediction in some wick samples.

Feasibility Studies on Selective Laser Melting of Copper Powders for the Development of High-temperature Circuit Carriers

2016 ◽  
Vol 2016 (1) ◽  
pp. 000517-000522
Author(s):  
Aarief Syed-Khaja ◽  
Christopher Kaestle ◽  
Joerg Franke
Keyword(s):  
High Temperature ◽  
Selective Laser Melting ◽  
Pure Copper ◽  
Feasibility Studies ◽  
Influential Factors ◽  
Powder Materials ◽  
Laser Melting ◽  
Bronze Alloy ◽  
Ceramic Surfaces ◽  
Copper Powders

Abstract Additive manufacturing (AM) has the potential to lead significant changes in the present state-of-the-art production processes. This provides tool-free and direct manufacturing of complex geometries simultaneously integrating various functions into components. Though AM techniques are widely used in various sectors, the application into electronics production has been not yet explored. In electronics production, substrate development has high relevance due to their multi-functionality in giving the mechanical support and electrically connecting electronic components. This contribution introduces an innovative approach in the development of high-temperature substrates through additive layered manufacturing. The technique used in the investigations was selective laser melting (SLM) of copper based powder materials mainly bronze alloy and pure copper, for the generation of conductive patterns on ceramic surfaces. The process parameters for the SLM technique and the influential factors in the generation of conductive structures are discussed in detail.

scholarly journals Microstructure and Conductivity of the Al-Cu Joint Processed by Friction Stir Welding

2020 ◽  
Vol 2020 ◽  
pp. 1-10 ◽  
Author(s):  
Yanni Wei ◽  
Hui Li ◽  
Peng Xiao ◽  
Juntao Zou
Keyword(s):  
Friction Stir Welding ◽  
Rotation Speed ◽  
Pure Copper ◽  
Compound Layer ◽  
Intermetallic Compound Layer ◽  
Interfacial Resistance ◽  
Cross Sectional ◽  
Interface Zone ◽  
Friction Stir ◽  
Good Surface

In this paper, 1060 aluminum and T2 pure copper were joined by friction stir welding. The influence of the rotation speed and inclination on the microstructure and mechanical properties of the joint were investigated. The microstructure and composition of the welded interface region were analyzed. The joints’ strength was tested, and the conductivity of the joints was estimated. Joints having good surface formation and defect-free cross section were successfully obtained. The cross-sectional morphologies of the Al-Cu friction stir welding joints can be divided into three zones: the shoulder impact zone, the weld nugget zone, and the interface zone. The interface zone consisted of a metallurgical reaction layer and a visible mixed structure. The reaction layers were identified as Al2Cu, Al4Cu9 phases. The tensile strength of the joints reaches maximum values of 102 MPa at a rotation speed of 950 rpm and inclination of 0°, which was approximately equal to those of 1060Al base metal. The resistivity of the Al-Cu joint was approximately equal to the theoretical resistivity. The interfacial resistance is directly affected by the joint defects, compound types, and thickness of the intermetallic compound layer.

Formation of Alumina Layer on Ti Alloy for Artificial Hip Joint

2014 ◽  
Vol 614 ◽  
pp. 200-205 ◽  
Author(s):  
Rohit Khanna ◽  
Tomiharu Matsushita ◽  
Tadashi Kokubo ◽  
Hiroaki Takadama
Keyword(s):  
Heat Treatment ◽  
Hip Joint ◽  
Thick Layer ◽  
Cold Spraying ◽  
Ti Alloy ◽  
Good Adhesion ◽  
Time Duration ◽  
Alumina Layer ◽  
Artificial Hip Joint ◽  
Artificial Hip

The purpose of this research is to form a layer of alumina on Ti-6Al-4V alloy for hip joint by deposition of Al layer on the Ti alloy and its subsequent oxidation. In this work, a thick layer of Al was deposited onto the Ti alloy by cold spraying. The reaction layer of Al3Ti was formed by heat treatment of cold sprayed Al at 640°C in air/Ar atmosphere to ensure a good adhesion between cold sprayed Al layer and the Ti alloy. A thick Al3Ti layer formed by heat treatment of Al layer at 640°C for 12 h in air, was subjected to heat treatment at 850°C for 96 h in air to form a-alumina and Al2Ti. Thus, alumina scales can be formed on the top surface of the Ti alloy and can be densified by increasing the time duration of heat treatment.

Strength and Hardness Assessment of Copper and Copper Alloy Coatings on Stainless Steel Substrates

2016 ◽  
Author(s):  
Mohamed Ibrahim ◽  
Khaled Al-Athel ◽  
Abul Fazal M. Arif
Keyword(s):  
Mechanical Properties ◽  
Stainless Steel ◽  
Adhesion Strength ◽  
Copper Alloy ◽  
Steel Substrate ◽  
Copper Alloys ◽  
Pure Copper ◽  
Coating Materials ◽  
Coating Composition ◽  
The Cross

Coatings are extensively used in many areas including industrial and medical fields to serve various functions as corrosion resistance, wear resistance and antibacterial purposes. Copper and copper alloys are among the most widely applied coating materials for several industrial and medical applications. One of their widely used copper coating applications is in the antibacterial coating area. Most of the research done in this field focuses on the antibacterial behavior with no comprehensive assessment regarding their mechanical properties, such as hardness and adhesion strength. In this work, mechanical assessment of strength and hardness of pure copper and several copper alloys including Cu Sn5% P0.6%, Cu Ni18 Zn14 (German silver), and Cu Al9 Fe1 are studied experimentally and numerically. All coatings are deposited on stainless steel substrate disks of 25mm diameter by wire-arc thermal spraying at the center of advanced coating technologies, University of Toronto. All coatings are 150 microns in thickness, with two additional thicknesses up to 350 microns for Cu Ni18 Zn14 (German silver) and Cu Al9 Fe1. The effect of the coating thickness and composition on the mechanical properties is studied for all the copper and copper alloy samples with the varying thicknesses between 150 and 350 microns. Scanning Electron Microscope (SEM) is used to study the surface as well as the cross-sectional microstructure of the coatings. Vickers micro-indentation tests are used to evaluate hardness at various locations on the cross-section of the coating and the substrate. This is used to evaluate the effect of the deposition of the coating material, and the subsequent solidification, on the hardness of the coating layer as well as the substrate near the coating interface. Pull-off adhesion tests are performed to evaluate the effect of the coating composition and thickness on the strength of the coatings. Tests are carried out to compute the pull-off failure stress that causes the delamination between the coating and the substrate. Computational analysis will be used to calibrate the experimental data when available by means of finite element analysis. The preliminary pull-off tests show interesting results as the samples with lower coating thicknesses exhibit delamination at higher strengths. This is due to the increase in residual stresses in higher thicknesses building up during the deposition process. Some of the samples did not even fail at lower thicknesses of 150 microns. A comprehensive analysis between the adhesion strength and hardness will be very useful in understanding the effect of coating composition and thickness on the mechanical properties of the coating.

Sign in / Sign up

Export Citation Format

Share Document