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<p>High-pressure compressed gases, such as nitrogen (N<sub>2</sub>) and helium (He), are critical for propelling micron-sized particles onto a substrate during the cold spray (CS) process. The propellant molecular weight and specific heat ratio affect the gas speed of sound, allowing for distinct flow acceleration and injected particle momentum transfer during CS for a set operating pressure and temperature. Since higher particle impact velocities can improve the overall CS deposit quality/efficiency, the present work focuses on investigating the effect of N<sub>2</sub> and He as process gases on the deposition of mechanically alloyed AlCoCrFeNi high-entropy alloy (HEA) particles with diameters ranging between 5 and 100&#xa0;µm onto high-strength low-alloy steel substrates. Moreover, this research examines the influence of various properties of both particle and substrate, such as density and dynamic yield strength, on the effective particle bonding, demonstrated by particle flattening ratio and critical bonding velocity. Based on the findings, the particle velocities ranged from 502 to 868&#xa0;m/s for coatings obtained with N<sub>2</sub> gas, compared to 717&#xa0;m/s to 1797&#xa0;m/s for those sprayed with He gas, resulting in more effective deposition of the latter. The evaluated critical velocity for AlCoCrFeNi particles onto low-alloy steel substrate is &gt; 1400&#xa0;m/s which delineates the onset of successful mechanical and metallurgical bonding. Deviations from the optimal deposition window may prompt particle rebounding and empty crater formation, particularly when employing N<sub>2</sub> as the propelling medium.</p>

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Propelling Gas Influence on the Deposition of AlCoCrFeNi High-Entropy Alloy Particles on a Steel Substrate Using Cold Spray

  • 期刊论文

  • 发表日期：

    2025年2月3日

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  • Aisa Grace D. Custodio,
  • Marvin S. Tolentino,
  • Aleksandra Nastic,
  • Bertrand Jodoin,
  • Gobinda C. Saha,
  • Clodualdo Aranas Jr.

摘要

High-pressure compressed gases, such as nitrogen (N2) and helium (He), are critical for propelling micron-sized particles onto a substrate during the cold spray (CS) process. The propellant molecular weight and specific heat ratio affect the gas speed of sound, allowing for distinct flow acceleration and injected particle momentum transfer during CS for a set operating pressure and temperature. Since higher particle impact velocities can improve the overall CS deposit quality/efficiency, the present work focuses on investigating the effect of N2 and He as process gases on the deposition of mechanically alloyed AlCoCrFeNi high-entropy alloy (HEA) particles with diameters ranging between 5 and 100 µm onto high-strength low-alloy steel substrates. Moreover, this research examines the influence of various properties of both particle and substrate, such as density and dynamic yield strength, on the effective particle bonding, demonstrated by particle flattening ratio and critical bonding velocity. Based on the findings, the particle velocities ranged from 502 to 868 m/s for coatings obtained with N2 gas, compared to 717 m/s to 1797 m/s for those sprayed with He gas, resulting in more effective deposition of the latter. The evaluated critical velocity for AlCoCrFeNi particles onto low-alloy steel substrate is > 1400 m/s which delineates the onset of successful mechanical and metallurgical bonding. Deviations from the optimal deposition window may prompt particle rebounding and empty crater formation, particularly when employing N2 as the propelling medium.