OPTIMIZATION OF Al-BASED AMORPHOUS COATINGS BY WARM SPRAYING BASED ON A NUMERICAL SIMULATION AND A RESPONSE-SURFACE METHODOLOGY
Keywords:
Al-based amorphous coatings, warm spraying, numerical simulation, response-surface methodolo
Abstract
Al-based fully amorphous coatings with low porosity were prepared using a warm-spraying technology by combining numerical simulations and a response-surface methodology (RSM). The influences of spraying parameters (reactant flow rate, oxygen/fuel (O/F) ratio, coolant flow rate, and spraying distance) on the particle temperature and velocity were investigated using numerical simulation methods. On this basis, the response-surface equations for temperature and the velocity of the particles were established using the Box-Behnken Design (BBD) methods. The RSM was used to analyze the influence of the interactions between the spraying parameters on the temperature and the velocity of the particles. The optimum spraying parameters (OSP) predicted by the response optimizer were 0.012047 kg/s for the reactant flow rate, 0.011034 kg/s for the coolant flow rate, 2.7 for the O/F ratio, and 142 mm for the spraying distance. According to the OSP, the Al-based fully amorphous coatings with a porosity of 0.08% were obtained by warm-spraying experiments. This work provides guidance for the production of Al-based fully amorphous coatings with low porosity using warm spraying.
References
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3 N. C. Wu, J. B. Lian, R. Wang, R. H. Li, W. Liu, Effect of element types on the glass forming ability of Al-TM-RE ternary metallic glasses using electron structure guiding, J. Alloys Compd., 723 (2017), 123–128, doi:10.1016/j.jallcom.2017.06.262
4 M. H. Gao, S. D. Zhang, B. J. Yang, S. Qiu, H. W. Wang, J. Q. Wang, Prominent inhibition efficiency of sodium nitrate to corrosion of Al-based amorphous alloy, Appl. Surf. Sci., 530 (2020), 147211, doi:10.1016/j.apsusc.2020.147211
5 L. M. Zhang, S. D. Zhang, A. L. Ma, H. X. Hu, Y. G. Zheng, B. J. Yang, J. Q. Wang, Influence of sealing treatment on the corrosion behavior of HVAF sprayed Al-based amorphous/nanocrystalline coating, Surf. Coat. Technol., 353 (2018), 263–273, doi:10.1016/j.surfcoat.2018.08.086
6 L. M. Zhang, S. D. Zhang, A. L. Ma, H. X. Hu, Y. G. Zheng, B. J. Yang, J. Q. Wang, Thermally induced structure evolution on the corrosion behavior of Al-Ni-Y amorphous alloys, Corros. Sci., 144 (2018), 172–183, doi:10.1016/j.corsci.2018.08.046
7 C. L. Tan, H. M. Zhu, T. C. Kuang, J. Shi, H. W. Liu, Z. W. Liu, Laser cladding Al-based amorphous-nanocrystalline composite coatings on AZ80 magnesium alloy under water cooling condition, J. Alloys Compd., 690 (2017), 108–115, doi:10.1016/j.jallcom.2016.08.082
8 C. G. Pei, Z. X. Guo, J. G. Xiao, Effect of laser remelting treatment on Al85Ni8Y4Ce3 amorphous coating, Surf. Eng., 37 (2021), 642–649, doi:10.1080/02670844.2020.1800347
9 J. Henao, A. Concustell, I. G. Cano, S. Dosta, N. Cinca, J. M. Guilemany, T. Suhonen, Novel Al-based metallic glass coatings by Cold Gas Spray, Mater. Des., 94 (2016), 253–261, doi:10.1016/j.matdes.2016.01.040
10 C. C. Sun, X. L. Zhou, C. Xie, L. L. Xu, R. Z. Li, B. B. Liu, Formation of Al-based amorphous/nanocrystalline coatings by cold spraying, Surf. Coat. Technol., 389 (2020), 125644, doi:10.1016/j.surfcoat.2020.125644
11 L. Jin, L. Zhang, K. G. Liu, Z. G. Che, K. Li, M. Zhang, B. Zhang, Preparation of Al-based amorphous coatings and their properties, J. R. Earths, 39 (2021), 340–347, doi:10.1016/j.jre.2020.04.018
12 F. Presuel-Moreno, M. A. Jakab, N. Tailleart, M. Goldman, J. R. Scully, Corrosion-resistant metallic coatings, Mater. Today, 11 (2008), 14–23, doi:10.1016/S1369-7021(08)70203-7
13 N. R. Tailleart, B. Gauthier, S. Eidelman, J. R. Scully, Metallurgical and physical factors controlling the multi-functional corrosion properties of pulsed thermal-sprayed Al-Co-Ce coatings, Corros. Sci., 68 (2012), 035006-1–035006-26, doi:10.5006/1.3693697
14 J. B. Cheng, B. L. Wang, Q. Liu, X. B. Liang, In-situ synthesis of novel Al-Fe-Si metallic glass coating by arc spraying, J. Alloys Compd., 716 (2017), 88–95, doi:10.1016/j.jallcom.2017.05.032
15 H. X. Chen, D. J. Kong, Effects of laser remelting speeds on microstructure, immersion corrosion, and electrochemical corrosion of arc–sprayed amorphous Al–Ti–Ni coatings, J. Alloys Compd., 771 (2019), 584–594, doi:10.1016/j.jallcom.2018.08.252
16 J. B. Cheng, Y. Feng, C. Yan, X. L. Hu, R. F. Li, X. B. Liang, Development and characterization of Al-based amorphous coating, JOM, 72 (2020), 745–753, doi:10.1007/s11837-019-03966-y
17 M. H. Gao, W. Y. Lu, B. J. Yang, S. D. Zhang, J. Q. Wang, High corrosion and wear resistance of Al-based amorphous metallic coating synthesized by HVAF spraying, J. Alloys Compd., 735 (2018), 1363–1373, doi:10.1016/j.jallcom.2017.11.274
18 Z. D. Zhou, Z. B. Zhang, Y. X. Chen, X. B. Liang, B. L. Shen, Composition optimization of Al-Ni-Ti alloys based on glass-forming ability and preparation of amorphous coating with good wear resistance by plasma spray, Surf. Coat. Technol., 408 (2021), 126800, doi:10.1016/j.surfcoat.2020.126800
19 H. Katanoda, T. Kiriaki, T. Tachibanaki, J. Kawakita, S. Kuroda, M. Fukuhara, Mathematical modeling and experimental validation of the warm spray (two-stage HVOF) Process, J. Therm. Spray Technol., 18 (2009), 401–410, doi:10.1007/s11666-009-9299-0
20 S. Kuroda, M. Watanabe, K. H. Kim, H. Katanoda, Current Status and Future Prospects of Warm Spray Technology, J. Therm. Spray Technol., 20 (2011), 653–676, doi:10.1016/B978-0-85709-769-9.00007-5
21 H. Jafari, S. Emami, Y. Mahmoudi, Numerical investigation of dual-stage high velocity oxy-fuel (HVOF) thermal spray process: A study on nozzle geometrical parameters, Appl. Therm. Eng., 111 (2017), 745–758, doi:10.1016/j.applthermaleng.2016.09.145
22 C. Pierlot, L. Pawlowski, M. Bigan, P. Chagnon, Design of experiments in thermal spraying: A review, Surf. Coat. Technol., 202 (2008), 4483–4490, doi:10.1016/j.surfcoat.2008.04.031
23 G. A. Clavijo-Mejía, D. G. Espinosa-Arbeláez, J. A. Hermann-Muñoz, A. L. Giraldo-Betancur, J. Muñoz-Saldaña, Effect of HVOF Process Parameters on TiO2 Coatings: An Approach Using DoE and First-Order Process Maps, J. Therm. Spray Technol., 28 (2019), 1160–1172, doi:10.1007/s11666-019-00895-9
24 W. Jibran, J. Hogan, A. McDonald, Towards optimization of thickness, hardness, and porosity of low-pressure cold sprayed WC-Ni coatings, Int. J. Adv. Manuf. Technol., 116 (2021), 2149–2160, doi:10.1007/s00170-021-07500-w
25 S. Sauceda, S. Lascano, J. Núñez, C. Parra, C. Arévalo, L. Béjar, Effect of HVOF processing parameters on Cr3C2–NiCr hard coatings deposited on AISI 4140 steel, Eng. Sci. Technol., 39 (2023), 101342, doi:10.1016/j.jestch.2023.101342
26 L. Qiao, Y. P. Wu, S. Hong, J. Cheng, Z. Wei, Influence of the high-velocity oxygen-fuel spray parameters on the porosity and corrosion resistance of iron-based amorphous coatings, Surf. Coat. Technol., 366 (2019), 296–302, doi:10.1016/j.surfcoat.2019.03.046
27 N. Pulido-González, S. García-Rodríguez, M. Campo, J. Rams, B. Torres, Application of DOE and ANOVA in Optimization of HVOF Spraying Parameters in the Development of New Ti Coatings, J. Therm. Spray Technol., 29 (2020), 384–399, doi:10.1007/s11666-020-00989-9
28 J. Cheng, Y. P. Wu, S. Hong, J. B. Cheng, L. Qiao, Y. J. Wang, S. S. Zhu, Spray parameters optimization, microstructure and corrosion behavior of high-velocity oxygen-fuel sprayed non-equiatomic CuAlNiTiSi medium-entropy alloy coatings, Intermetallics, 142 (2022), 107442, doi:10.1016/j.intermet.2021.107442
29 S. J. S. Chelladurai, K. Murugan, A. P. Ray, M. Upadhyaya, V. Narasimharaj, S. Gnanasekaran, Optimization of process parameters using response surface methodology: A review, Mater. Today: Proc., 37 (2021), 1301–1304, doi:10.1016/j.matpr.2020.06.466
30 B. Y. Han, J. J. Chu, W. B. Du, K. B. Zhou, M. Q. Cong, F. F. Cui, W. X. Hang, S. Zhu, Optimization of Ni60A Coating Quality by Supersonic Plasma Spraying Based on Response Surface Methodology, J. Therm. Spray Technol., 32 (2023), 1596–1610, doi:10.1007/s11666-023-01580-8
31 K. Palanisamy, S. Gangolu, J. M. Antony, Effects of HVOF spray parameters on porosity and hardness of 316L SS coated Mg AZ80 alloy, Surf. Coat. Technol., 448 (2022), 128898, doi:10.1016/j.surfcoat.2022.128898
32 X. Gao, C. Li, D. C. Zhang, H. X. Gao, X. Han, Numerical analysis of the activated combustion high-velocity air-fuel (AC-HVAF) thermal spray process: A survey on the parameters of operation and nozzle geometry, Surf. Coat. Technol., 405 (2021), 126588, doi:10.1016/j.surfcoat.2020.126588
33 J. Z. Ren, G. F. Zhang, Y. M. Rong, Y. S. Ma, A feature-based model for optimizing HVOF process by combining numerical simulation with experimental verification, J. Manuf. Process., 64 (2021), 224–238, doi:10.1016/j.jmapro.2021.01.017
34 X. Y. Zhao, C. Li, S. Y. Li, H. S. Jiang, X. Han, Time-varying evolutionary mechanism analysis of the multiphase flow during high-velocity oxygen-fuel (HVOF) thermal spraying WC-12Co particle, Surf. Coat. Technol., 461 (2023), 129435, doi:10.1016/j.surfcoat.2023.129435
35 X. X. Chen, C. Li, S. Y. Li, X. Han, H. S. Jiang, X. Y. Zhao, HVOF Spray Performance Optimization Analysis and Experimental Research of WC–12Co Coating on Ti Alloy, Met. Mater. Int., 29 (2023), 3548–3565, doi:10.1007/s12540-023-01458-y
36 C. Li, X. Gao, Y. P. Yang, X. X. Chen, X. Han, Sensitivity Analysis of Process Parameters of Warm Spraying Process Based on Response Surface Method, J. Therm. Spray Technol., 31 (2022), 585–597, doi:10.1007/s11666-022-01319-x
37 M. M. Liu, Z. X. Yu, Y. C. Zhang, H. J. Wu, H. L. Liao, S. H. Deng, Prediction and analysis of high velocity oxy fuel (HVOF) sprayed coating using artificial neural network, Surf. Coat. Technol., 378 (2019), 124988, doi:10.1016/j.surfcoat.2019.124988
38 M. M. Liu, Research and implementation of artificial neural networks models for high velocity oxygen fuel thermal spraying, Université Bourgogne Franche-Comté, (2020)
39 K. Malamousi, K. Delibasis, B. Allcock, S. Kamnis, Digital transformation of thermal and cold spray processes with emphasis on machine learning, Surf. Coat. Technol., 433 (2022), 128138, doi:10.1016/j.surfcoat.2022.128138
40 U. M. R. Paturi, D. G. Vanga, S. Cheruku, S. T. Palakurthy, N. K. Jha, Estimation of abrasive wear of nanostructured WC-10Co-4Cr TIG weld cladding using neural network and fuzzy logic approach, Mater. Today: Proc., 78 (2023), 449–457, doi:10.1016/j.matpr.2022.10.266
41 J. X. Yu, X. Liu, Y. Yu, Z. M. Li, S. B. Xu, H. D. Li, P. F. Liu, L. M. Wang, Effect of HVOF Spraying Process on Particle Behavior of Fe-Based Amorphous Alloy Coatings, J. Therm. Spray Technol., 31 (2022), 2448–2462, doi:10.1007/s11666-022-01476-z
Published
2024-12-05
How to Cite
1.
Wang D, Li T, Wu N. OPTIMIZATION OF Al-BASED AMORPHOUS COATINGS BY WARM SPRAYING BASED ON A NUMERICAL SIMULATION AND A RESPONSE-SURFACE METHODOLOGY. MatTech [Internet]. 2024Dec.5 [cited 2026Oct.11];58(6):819–832. Available from: https://mater-tehnol.si/index.php/MatTech/article/view/1247
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