Research Summaries

Back Effects of Cold Spray Repairs on the Mechanical Properties of a Component

Fiscal Year 2021
Division Research & Sponsored Programs
Department NPS Naval Research Program
Investigator(s) Ansell, Troy
Nieto, Andy
Sponsor Office of the Chief of Naval Operations (Navy)
Summary Cold sprayed coatings and deposits for repair are being transitioned into field ready applications throughout DoD, with the projected use of cold spray expected to continue to rise. Cold spray deposits have many advantages, in terms of strength, low temperature processing, and scalability to very large components. An important assessment will be how these coatings and deposits affect mechanical performance. The overall objective of this study is to attempt to quantify changes in the factor of safety when an Cu-Ni material is cold sprayed with a Cu-Ni coating or deposit. The mechanical performance of cold sprayed coatings on Cu-Ni substrates will be evaluated in tension and under fatigue loadings. Of particular interest will be the material response at the interface between Cu-Ni cold sprayed coating and the Cu-Ni substrate or component. As such, the adhesion strength of cold sprayed deposits will be quantified as well thru standardized pull-tests. Surface conditions can alter adhesion strength, and hence Cu-Ni substrates will be cold sprayed either in an as-machined state or a grit blasted condition. Mechanical testing will be followed by detailed characterization of fracture surfaces and cross-sections of the coating-substrate interface, which will be compared with untested specimens. Fatigue and other mechanical and materials data will be fed into existing factor-of-safety models to quantify changes in the factor of safety.
Keywords Cold Spray Fatigue
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