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<p>Cold spray has been used extensively to repair critical military and aerospace components, particularly aluminum and magnesium parts. To achieve high strength and excellent ductility, many repairs have been developed using helium process gas. Unfortunately, the high cost and limited supply of helium require alternative processing methodologies. This study evaluated the influence of in situ peening via ~ 50&#xa0;mm ZrO<sub>2</sub>-based particles on the deposition characteristics, microstructure, and mechanical properties of nitrogen-deposited Al6061 cold spray coatings. Three powder mixtures comprising Al6061 and 25, 50, and 75 wt% ZrO<sub>2</sub> powder were deposited using nitrogen gas on Al6061 and ZE41 magnesium substrates. Results were compared to 100% Al6061 coatings produced using nitrogen and helium. In situ peening resulted in signification plastic deformation of the Al6061 deposit, which scaled with increasing ZrO<sub>2</sub> content, resulting in increasing levels of dynamic recrystallization that exceeded helium deposited coatings. Al6061-ZrO<sub>2</sub> coatings exhibited up to 11-13% higher microhardness, 10-21% higher adhesion strength, and 30-33% lower mass loss, but with 12-28% lower tensile strength compared to helium deposited coatings. The latter was attributed to reduced particle-particle cohesive strength. All coatings exhibited compressive residual stress, which decreased with increasing ZrO<sub>2</sub> content due to widespread dynamic recrystallization. The findings from this study show the potential to achieve “helium-like” properties for Al6061 coatings produced with nitrogen gas.</p>

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Effect of ZrO2 Peening Media on Microstructure and Mechanical Behavior of Al6061 Cold Spray Coatings

  • 期刊论文

  • 发表日期：

    2025年12月29日

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  • Leila Sorkhi,
  • Michael Carter,
  • Nathan Staley,
  • Wade Lein,
  • Grant Crawford

摘要

Cold spray has been used extensively to repair critical military and aerospace components, particularly aluminum and magnesium parts. To achieve high strength and excellent ductility, many repairs have been developed using helium process gas. Unfortunately, the high cost and limited supply of helium require alternative processing methodologies. This study evaluated the influence of in situ peening via ~ 50 mm ZrO2-based particles on the deposition characteristics, microstructure, and mechanical properties of nitrogen-deposited Al6061 cold spray coatings. Three powder mixtures comprising Al6061 and 25, 50, and 75 wt% ZrO2 powder were deposited using nitrogen gas on Al6061 and ZE41 magnesium substrates. Results were compared to 100% Al6061 coatings produced using nitrogen and helium. In situ peening resulted in signification plastic deformation of the Al6061 deposit, which scaled with increasing ZrO2 content, resulting in increasing levels of dynamic recrystallization that exceeded helium deposited coatings. Al6061-ZrO2 coatings exhibited up to 11-13% higher microhardness, 10-21% higher adhesion strength, and 30-33% lower mass loss, but with 12-28% lower tensile strength compared to helium deposited coatings. The latter was attributed to reduced particle-particle cohesive strength. All coatings exhibited compressive residual stress, which decreased with increasing ZrO2 content due to widespread dynamic recrystallization. The findings from this study show the potential to achieve “helium-like” properties for Al6061 coatings produced with nitrogen gas.