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<p>Cold spray deposition was investigated as a candidate technology for producing corrosion- and abrasion-resistant coatings for deep borehole nuclear waste disposal canisters. Commercially pure grade 2 Ti, Cu, Cu-1&#xa0;wt.% alumina and Inconel 625 were deposited on AISI C1020 steel with thicknesses between 0.9 and 3.2&#xa0;mm. Coating adhesion to steel was generally poor under nitrogen propellant but improved when the initial layer was deposited using helium. All coatings exhibited residual porosity. Post-spray heat treatments were applied to reduce open porosity: laser glazing for Ti and Inconel 625 and furnace heat treatment (350&#xa0;°C, 1&#xa0;h in air) for the Cu-based coatings. Laser treatment significantly refined the microstructure and reduced open porosity in the Ti coatings. Electrochemical testing in 0.1&#xa0;M NaCl confirmed that corrosion resistance increased markedly with coating thickness and was substantially higher for Ti and Inconel 625 than for the Cu-based coatings. Furnace heat treatment enhanced corrosion resistance by approximately one order of magnitude, whereas laser glazing improved performance by roughly two orders of magnitude. Abrasion resistance (ASTM G65-00) decreased in the order: Inconel 625 &gt;  &gt; Cu + alumina ≈ Cu &gt; CP2-Ti. Laser glazing improved the abrasion resistance of Ti by ~ 70%, surpassing Cu + alumina, whereas heat treatments had minimal influence on the other materials. Microhardness increased significantly after cold spray due to severe plastic deformation and was partially restored toward feedstock values after heat exposure for Cu-based and Inconel 625 coatings. Laser glazing nearly doubled the hardness of Ti owing to surface TiN formation. These results emphasize the critical role of eliminating open porosity to achieve high corrosion resistance in cold-sprayed coatings, while also identifying strategies for improving abrasion resistance in coatings intended for deep borehole disposal applications.</p>

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Corrosion and Abrasion Resistance of Titanium, Copper and Inconel 625 Cold Spray Coatings

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年8月5日

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  • Christian Doblin,
  • Paul A. White

摘要

Cold spray deposition was investigated as a candidate technology for producing corrosion- and abrasion-resistant coatings for deep borehole nuclear waste disposal canisters. Commercially pure grade 2 Ti, Cu, Cu-1 wt.% alumina and Inconel 625 were deposited on AISI C1020 steel with thicknesses between 0.9 and 3.2 mm. Coating adhesion to steel was generally poor under nitrogen propellant but improved when the initial layer was deposited using helium. All coatings exhibited residual porosity. Post-spray heat treatments were applied to reduce open porosity: laser glazing for Ti and Inconel 625 and furnace heat treatment (350 °C, 1 h in air) for the Cu-based coatings. Laser treatment significantly refined the microstructure and reduced open porosity in the Ti coatings. Electrochemical testing in 0.1 M NaCl confirmed that corrosion resistance increased markedly with coating thickness and was substantially higher for Ti and Inconel 625 than for the Cu-based coatings. Furnace heat treatment enhanced corrosion resistance by approximately one order of magnitude, whereas laser glazing improved performance by roughly two orders of magnitude. Abrasion resistance (ASTM G65-00) decreased in the order: Inconel 625 >  > Cu + alumina ≈ Cu > CP2-Ti. Laser glazing improved the abrasion resistance of Ti by ~ 70%, surpassing Cu + alumina, whereas heat treatments had minimal influence on the other materials. Microhardness increased significantly after cold spray due to severe plastic deformation and was partially restored toward feedstock values after heat exposure for Cu-based and Inconel 625 coatings. Laser glazing nearly doubled the hardness of Ti owing to surface TiN formation. These results emphasize the critical role of eliminating open porosity to achieve high corrosion resistance in cold-sprayed coatings, while also identifying strategies for improving abrasion resistance in coatings intended for deep borehole disposal applications.