Supersonic Particle Deposition (Cold Spray) Phillip F. Leyman US Army Research Laboratory Weapons & Materials Research Directorate Presented at HCAT Program Review Meeting July 20-21 2004
Report Documentation Page Form Approved OMB No. 0704-0188 Public reporting burden for the collection of information is estimated to average 1 hour per response, including the time for reviewing instructions, searching existing data sources, gathering and maintaining the data needed, and completing and reviewing the collection of information. Send comments regarding this burden estimate or any other aspect of this collection of information, including suggestions for reducing this burden, to Washington Headquarters Services, Directorate for Information Operations and Reports, 1215 Jefferson Davis Highway, Suite 1204, Arlington VA 22202-4302. Respondents should be aware that notwithstanding any other provision of law, no person shall be subject to a penalty for failing to comply with a collection of information if it does not display a currently valid OMB control number. 1. REPORT DATE JUL 2004 2. REPORT TYPE 3. DATES COVERED 00-00-2004 to 00-00-2004 4. TITLE AND SUBTITLE Supersonic Particle Deposition (Cold Spray) 5a. CONTRACT NUMBER 5b. GRANT NUMBER 5c. PROGRAM ELEMENT NUMBER 6. AUTHOR(S) 5d. PROJECT NUMBER 5e. TASK NUMBER 5f. WORK UNIT NUMBER 7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES) U. S. Army Research Laboratory,Weapons & Materials Research Directorate,Aberdeen Proving Ground,MD,21005 8. PERFORMING ORGANIZATION REPORT NUMBER 9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES) 10. SPONSOR/MONITOR S ACRONYM(S) 12. DISTRIBUTION/AVAILABILITY STATEMENT Approved for public release; distribution unlimited 11. SPONSOR/MONITOR S REPORT NUMBER(S) 13. SUPPLEMENTARY NOTES 24th Replacement of Hard Chrome Plating Program Review Meeting, July 20-21, 2004, Park City, UT. Sponsored by SERDP/ESTCP. 14. ABSTRACT 15. SUBJECT TERMS 16. SECURITY CLASSIFICATION OF: 17. LIMITATION OF ABSTRACT a. REPORT unclassified b. ABSTRACT unclassified c. THIS PAGE unclassified Same as Report (SAR) 18. NUMBER OF PAGES 24 19a. NAME OF RESPONSIBLE PERSON Standard Form 298 (Rev. 8-98) Prescribed by ANSI Std Z39-18
SPD vs. vs. Thermal Thermal Spray Spray SPD SPDuses useslower lowertemperatures, temperatures,but buthigher higherparticle particlevelocities velocities SPD
Supersonic Particle Deposition Gas Control Module N 2 or He gas Electric Heater Coating and Substrate Powder Feeder Supersonic Nozzle
System Arrangement
Army Research Laboratory SPD System
SPD Advantages Advantages SPD Low temperature temperature Low SolidState StateProcess Process Solid Lowresidual residualstresses stresses Low Minimalgrain graingrowth growth Minimal Little oxidation oxidation Little goodelectrical/thermal electrical/thermalconductivity conductivity good electricalconductivity: conductivity:80% 80%of ofofhc OFHCCopper Copper electrical High deposition deposition rates rates and and efficiencies efficiencies High rates--up upto to20 20kg/hr. kg/hr. rates efficienciesgenerally generally50 50--80% 80% efficiencies Wide variety variety of of coating coating materials materials and and Wide substrates substrates Al,Zn, Zn,Sn, Sn,Cu, Cu,Ni, Ni,Ti, Ti,Ta, Ta,Co, Co,Fe, Fe,Nb, Nb,Mo, Mo,W. W. Al,
Model of Particle Impact* 5 nsec 20 nsec 35 nsec 50 nsec *M. Grujicic,et al, Computational Analysis of the Interfacial Bonding Between Feed-Powder Particles and the Substrate in the Cold-Gas Dynamic-Spray Process, Applied Surface Science, April 2003
Process Parameters N 2 or He gas 200 500 psi gas pressure 200 500 degree C gas temperature 100 300 degree C particle temperature 1 50 micron particle diameter 300 1000 meter per second particle velocity 1 10 pounds per hour deposition rate
Effects of of Gas Gas Pressure Pressure Effects and Temperature Temperature on on Velocity Velocity and Particle Velocity (m/s) 575 550 525 500 200 psi 475 300 psi 450 380 psi 425 400 0 100 200 300 400 Gas Temperature (C) 500
Effect of of Velocity Velocity on on Deposition Deposition Effect Deposition Efficiency, % 100 80 60 40 20 0 400 500 600 700 800 900 Particle Velocity, m/s From Gilmore, et al, J. Thermal Spray Tech, Dec. 1999
Copper Deposited On Aluminum Rod
Magnified Interface (Super Plastic Agglomerated Mixing)
EDS X-ray X Mapping of SPAM Forced mixing of copper and aluminum. Forced mixing of copper and aluminum. Copper SPD Coating Aluminum Substrate BEI SEI
Shear Test Results (Triple Lug Shear Test) Trial Pressure psi Temperature degree C Stand-off mm Speed mm/sec Feed rate gm/min Shear strength psi 1 280 450 35 50 7 5347 2 280 350 15 50 28 6072 3 380 450 35 10 28 6683 4 380 350 15 10 7 10057 Failure Mode = Cohesive
Adhesion Values of Coating (Bond Bars) Coating Thickness Ultimate Tensile Strength NiAl 0.015 in 5,000 psi Tantalum 0.010 in 8,000 psi Copper 0.010 in 6,800 psi Failure Mode = Adhesive All values of adhesion were of coatings deposited on aluminum
8 Particle Velocity Distribution Measured by DPV 2000 20 micron copper particles 25 mm downstream 400 psi, 400 C N 2 gas Millimeters 6 4 2 0 0 2 4 6 8 Millimeters 500 m/sec 600 m/sec 700 m/sec 800 m/sec 900 m/sec
SPD Copper Copper on on Silicon Silicon Carbide Carbide SPD
Copper on on Silicon Silicon Carbide Carbide Copper Bond Strength Strength (Pull (Pull Test) Test) Bond Film Thickness Thickness Film Cu Resistivity Resistivity (Theoretical) (Theoretical) Cu Cu Resistivity Resistivity (Electronics) (Electronics) Cu Cu Resistivity Resistivity (Cold (Cold Spray) Spray) Cu 1500 lbs/in lbs/in22 1500 1-2 mils mils 1-2 -6 ohm-cm -6 1.7 x 10 1.7 x 10 ohm-cm -6 ohm-cm -6 2.0 x 10 2.0 x 10 ohm-cm -6 ohm-cm -6 4.5 x 10 4.5 x 10 ohm-cm
Dymet Portable Cold Spray Downstream Powder Feed Portability Slightly Lower Particle Velocity Special Powder Formulation
SPD and DYMET Velocity and Particle Flux Profiles 12 10 4 2e+4 millimeters 2 0-2 2e+4 2e+4 4e+4 2e+4 4e+4 6e+4 6e+4 8e+4 6e+48e+4 1e+5 4e+4 1e+5 6e+4 4e+4 2e+4 8e+4 2e+4 2e+4 4e+4 6e+4 4e+4 2e+4 millimeters 8 6 4 10000 10000 20000 10000 10000 20000 20000 10000 30000 30000 40000 40000 50000 50000 20000 30000 60000 50000 40000 30000 10000 40000 30000 20000 20000 10000 10000 2-4 -4-2 0 2 4 400 500 600 700 800 millimeters 0 0 2 4 6 8 10 12 200 300 400 500 600 700 800 millimeters
EMICoating Coatingfor forhumv HUMVShelter Shelter(SPD) (SPD) EMI 6061-T6 Al Cross-section Composite Lap joint Enlarged Supersonic Particle Deposition
MetallographicCross-Sections Cross-Sectionsof ofemi EMICoatings Coatings Metallographic SupersonicParticle ParticleDeposition Deposition Supersonic.072 in.031 in Aluminum Lap Joint.032 step height Al Coating Hand-heldportable portablespd SPDSystem System Hand-held
FlameSpray Sprayvs. vs.supersonic SupersonicParticle ParticleDeposition Deposition Flame Sn Coating 6061-T6 Aluminum Flame Spray Sn and Steel Coating ~12.2% Porosity SPD Sprayed Sn Coating ~.18% Porosity
Conclusions Supersonic particle deposition can yield an exceptionally strong bond The bond can be characterized as Super Plastic Agglomerate Mixing High velocity impact yields plastic deformation and viscous mixing of the particle/substrate interface The resulting bond exhibits shear resistance greater than the shear strength of the copper coating.