Session: 04 - 01 Emerging Techniques & Technology

Paper Number: 118597

118597 - Nondestructive Evaluation of the Effects of System Parameters on the Properties of Aa 6061 Cold Spray Coatings 

Nondestructive evaluation of the effects of System Parameters on the Properties of AA 6061 Cold Spray Coatings

Shamachary Sathish, Saikumar Chalivendra, Giacomo Flora, Jon-Russell Groenewegen,

Michael Froning*

University of Dayton Research Institute, 300 College Park, Dayton, OH, 45429

*United States Air Force, AFLCMC/EN-EZ/EZPT, WPAFB, OH 45433

ABSTRACT

Cold spray is a solid-state coating process consolidating high-velocity metallic powder particles, accelerated by a high-speed gas jet onto a substrate. In the process of coating formation, the temperature of the metallic particle does not reach melting temperature; thus, the coatings are free of oxidation, grain growth, chemical reaction, and microstructure changes in the powder. In the last decade, many advantages of cold spray technology have been used to qualify cold spray coatings to repair aircraft components. The qualification process predominantly depends on destructive measurement of hardness, porosity, and bond strength thru “proof testing.” While destructive methods are necessary to establish optimized parameters to produce high-quality cold spray coatings with low porosity, hardness, and excellent bond strength, nondestructive (NDE) methods are critical in evaluating coatings on repaired aircraft components. This paper presents results and analysis of NDE x-ray diffraction and the eddy current in AA 6061 coatings on AA2024-T6 substrate manufactured with varying cold spray parameters. X-ray diffraction was used to measure local residual stress and the Full Width at Half Maximum (FWHM). The eddy current method was used to measure local relative electrical conductivity. The x-ray diffraction results showed a small compressive residual stress independent of the cold spray parameters. On the other hand, the FWHM and the electrical conductivity are observed to increase with changes in cold spray parameters and correlate with the micro-hardness of the coatings. The results of NDE measurements are discussed,  i) to optimize cold spray parameters to produce coatings with optimized properties and ii) to evaluate the quality of cold spray coatings on repaired aircraft components.

Presenting Author: Jon-Russell Groenewegen UDRI

Presenting Author Biography: Bio will be provided with approved abstract