Documenti di Didattica
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Features
Award-Winning 1937 Alfa Romeo Gets a
Boost with Cold Spray................................................................................ 4
4
Cold Spray vs. Thermal Spray: From Dimensional
Restoration to Additive Manufacturing................................................. 8
Departments
Industry News............................................................................................11
8 Product Spotlight.......................................................................................14
ITSA Member News..................................................................................16
ITSA Membership......................................................................................20
Calendar.......................................................................................................22
Cover photo: A manual repair being performed on an aircraft component using a portable high-pressure cold
22
spray system. (Photo courtesy of the Cold Spray Synergy Site, Webster, Mass.)
Published by International Thermal Spray Association, SPRAYTIME® (ISSN 1532-9585) is a quarterly publication of the
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The 1937 Alfa Romeo 8C 2900B Touring Berlinetta won the 2018 Best of Show award at the Pebble Beach Concours d’ Elegance. (David and Ginny Sydorick,
Beverly Hills, Calif. Copyright Kimball Studios / Courtesy of Pebble Beach Concours d’ Elegance.)
A
lthough less powerful than its predecessors, the Alfa effort to search for modern repair techniques that would restore
Romeo 8C 2900B Touring Berlinetta was exclusively functionality while not compromising mechanical integrity and
designed for select customers of the automaker. It improving aesthetics.
later became an attractive vintage item to avid international
automotive collectors. The car is believed to have been kept in
Germany through World War II and into the 1950s. In 1956, the
vehicle was purchased by an American collector and imported The Cold Spray Choice
into the United States for the first time. Initially restored in
the 1990s, it spent time on both sides of the Atlantic over the Cold spray is a solid-state metal consolidation process that
years before finally joining the collection of David and Ginny uses a high-speed gas jet to propel metal and other powder
Sydorick. In 2001, an early production of the vehicle won the particles against a substrate where particles plastically deform
Most Elegant Closed Car award at the Pebble Beach Concours and consolidate upon impact. The term “cold spray” refers to
d’Elegance. The automotive event is an annual display of the relatively low temperature involved in the process, which
historic and beautiful cars and considered to be the world’s is typically much lower than the melting point of the spray
most prestigious. In 2018, the Sydorick car, fresh from its material and substrate. Since adhesion of the metal powder to the
recent restoration, won the ultimate prize Best of Show at the substrate and deposited material is achieved in the solid state,
renowned car show. It also received two other awards at the the characteristics of cold spray deposits are quite unique, making
show, the Charles A. Chayne Trophy and the J. B. & Dorothy cold spray suitable for depositing well-bonded, low-porosity,
Nethercutt Most Elegant Closed Car. oxide-free deposits. These attributes make cold spray uniquely
suitable for depositing a range of temperature-sensitive materials
in this application.
Portable cold spray equipment offered an economically viable
option to conduct the repair using nitrogen as a propellant and
Challenges during Restoration aluminum-based powder as the repair material — Fig. 2. After
low-temperature dimensional restoration of the area, the new
In trying to restore the car to its original condition under consolidated material was effectively machined back to tolerance
the hood, many challenges were faced. Corrosion, tear, and using standard machining techniques.
wear had damaged both the aesthetics and functionality of the
cast aluminum oil pan. There were visible cracks on the inside,
unacceptable aesthetics on the outside, and multiple oil leaks
during operation — Fig. 1. The aluminum cast alloys used to The Procedure
fabricate these components were all heat treated, making them
quite sensitive to thermal repair processes such as welding or The cold spray processes began with surface preparation,
conventional thermal spray, for degraded mechanical properties which consisted of cleaning, pre-machining for suitable
and distortion. Replacing the old part with a new one wasn’t deposition, and grit blasting. Then, an SST TM Series P machine
an option because these components went out of production was utilized to manually fill in all repair areas, using the spray
a long time ago. Attempts had been made to dimensionally parameters depicted in Table 1. The sprayed component was
repair these defects by special welding methods, which still finally machined to desired dimensional tolerances — Fig. 3.
rendered poor performance results and worsened the aesthetic The vehicle was then reassembled by a professional restoration
appearance. Consequently, the restoration professionals made an shop (Ref. 1) to its original functionality and aesthetics — Fig. 4.
Gas: Nitrogen
o
Gas Temperature: 450 C
Conclusion
After several attempts in the quest for appropriate repair
technologies, the professional restorer was able to salvage and
restore the irreplaceable oil pan back to its original condition
thanks to the use of cold spray.
References
1. RX Autoworks, Vancouver, British Columbia, Canada,
rxautoworks.com.
Fig. 2 — The commercial SST TM Series P cold spray system was used to Julio Villafuerte (julio.villafuerte@cntrline.com) is
conduct the oil pan restoration job. (Courtesy of CenterLine Windsor Ltd.) corporate technology strategist at CenterLine Windsor Ltd.,
Windsor, Ontario, Canada.
Fig. 3 — Restored oil pan. (Courtesy of RX Autoworks.) Fig. 4 — The vehicle is reassembled following the restoration of the oil pan.
(Courtesy of RX Autoworks.)
C
old spray is often compared to One of the most deleterious effects of concentration. Good corrosion protection
traditional thermal spray processes. depositing materials at high temperatures is also achieved by dense, impermeable,
Although there are certain is the tensile residual stresses that develop, cold sprayed coatings. Sometimes thermal
similarities, it is important to recognize especially at the substrate-coating inter- spray can result in particles imbedded in
the fundamental differences between the face, which is the result of the thermal the microstructure that solidified during
two techniques to determine which is contraction of the molten particles upon flight, prior to impacting the substrate, and
best suited for various combinations of solidification (Refs. 2, 3, 4, 5). This can have a distinctive oxide layer surrounding
substrate and coating materials, as well as become a particular concern in an them (Ref. 9).
for the application. application requiring a relatively thick Except for some of the high-velocity
Cold spray technology is the logical deposit because these stresses often cause oxyfuel (HVOF) coatings that contain
choice for dimensional restoration of delamination and often limit the maximum carbides or extremely hard particles,
a variety of engineering materials and deposit thickness that can be achieved. there is a significant difference between
applications where the high temperatures This problem is compounded when the the bonding mechanism of thermal spray
associated with conventional thermal substrate material is different from the and cold spray. Shear strength test results
spray technology can result in undesirable coating material in terms of hardness and for a series of 6061 aluminum (Al) cold
metallurgical transformations, including density, and there is a significant variation spray deposits on ZE41A-T5 Mg have
grain growth, as well as oxidation, that in the coefficient of thermal expansion. been reported by Champagne III et al. in
can have detrimental effects on bond In contrast, there is very little their investigation of joining cast ZE41A-
strength and porosity and/or damage thermally-induced dimensional change of Mg to wrought 6061 Al by the cold spray
the underlying substrate. Substrates that the cold spray material since consolidation process and friction stir welding (Ref.
are sensitive to high temperatures may of the particles takes place in the solid 10) using MIL-J-24445A. The average
preclude the use of thermal spray and state. Also, the significantly high impact ultimate tensile strength (UTS) obtained
would include magnesium, composites, velocities of the solid particulates are was 163 ± 3.8 MPa, and values as high as
and other low-melting alloys. Magnesium very effective at peening the underlying 184 MPa (26.7 ksi) were achieved, which
readily reacts with molten metal deposited material and producing deposits, which are was equivalent to that of the magnesium
by thermal spray and oxidizes, causing typically in a state of compressive stress substrate and was significantly higher
poor adhesion (Ref. 1). Cold spray below a certain thickness range (Refs. than thermal spray. The cold spray
incorporates very high particle velocities 6, 7). In addition, interfacial instability coating remained adhered to the ZE41A
(300–1500 m/s) to achieve consolidation, due to differing viscosities, along with magnesium substrate and did not become
and gas temperatures can be adjusted to the resulting interfacial roll-ups and detached subsequent to shear testing.
avoid undesirable transformations of the vortices, promote interfacial bonding by Figure 2 shows the 6061 Al cold spray
feedstock powder, the resultant deposit, increasing the interfacial area, giving rise coating was so strong the failure occurred
and the substrate, yielding a deposit with to material mixing at the interface and in the ZE41A magnesium substrate.
low porosity, plus high bond and increased providing mechanical interlocking between Chunks of the magnesium substrate can be
cohesive strength — Fig. 1. the two materials (Ref. 8). Adhesion of seen in Fig. 2.
thermal spray coatings relies primarily Plasma and HVOF thermal spray
upon the surface finish referred to as the have been investigated for deposition of
anchor tooth profile of the substrate. aluminum for dimensional restoration of
The molten particles or ‘splats,’ which are magnesium aerospace components, but the
propelled onto the substrate penetrate results have generally been unsatisfactory
and subsequently solidify, lock themselves due to inconsistent coating integrity. Poor
mechanically within the valleys of the adhesion and delamination of the coatings
surface profile. are typically the cause for high rejection
In comparison with conventional rates because both of these processes
Fig. 1 — SEM of 6061 Al joined to ZE41A-T5 thermal spray techniques, the materials involve the use of high thermal energy to
Mg showing a very dense deposit and no produced by cold spray are typically less melt or partially melt the coating material
evidence of intermetallic compounds at the porous, with higher hardness and before it is propelled against the surface of
interface.
conductivity, and lower oxide the substrate. The tiny molten or partially
Here’s an easy breakdown of our guidelines: If you’d like to discuss a particular idea or email a
l The text of the article should be about 1500 to 2000
submission for evaluation, please contact
words and provided in a Word document. Editor Cindy Weihl at cweihl@thermalspray.org.
3rd ANNUAL
ADVANCED COATINGS
SYMPOSIUM
“AEROSPACE”
Annual ITSA Membership Meeting
AWS C2 Committee Meetings on Thermal Spray Standards
The International Thermal Spray • Scott Wilson, Oerlikon, overview of turbomachinery sealing
Association’s (ITSA’s) 3rd Annual applications and challenges
Advanced Coatings Symposium • Tom Menke and Lew Temples (authors) (presented by Dick
(Aerospace) & Annual Membership Mason), Powder Alloy Corp., low temperature abradable coating
Meeting will take place October 7-10 at materials
the MGM – Springfield in Springfield, • Winnie Tan, Siemens, high temperature compressor
Mass. abradable coatings for gas turbine applications
During the event, the latest • Andrea Scrivani, Höganäs, development of advanced
technology in aerospace repair will be thermal barrier coating for improving gas turbine components
covered, along with high-temperature, lifetime
wear-resistant, and clearance-control • Eric Jordan, UConn, damage under the gradual application
coatings. of heterogeneous calcium-magnesium-aluminosilicates
The keynote speaker, Brian Hazel, • Rogerio Lima, NRC, increasing deposition efficiency
is a technical fellow with the coatings and maintaining the high temperature performance of yttria-
Brian Hazel will present in materials and process engineering stabilized zirconia thermal barrier coatings: changing from Ar-H2
the keynote speech at group at Pratt & Whitney. He has 19 to N2-H2 plasma in legacy atmospheric plasma spraying torches
ITSA’s 2019 symposium.
years of experience in gas turbine • David Wright, Accuwright, practical advancements of cold
material development, including work gas dynamic spray
in thermal barrier coatings, environmental barrier coatings, • Vic Champagne, CIV U.S. Army Futures Command (USA),
bond/corrosion-resistant coatings, and single crystal superalloys. advancements in cold spray technology
Among his accomplishments are more than 40 patents in the • Christopher Berndt, SEAM (Surface Engineering for
area of high-temperature coatings, with emphasis on thermal Advanced Materials), thermal spray coatings for sub- and
and environmental barrier coatings, as well as corrosion-resistant supersonic applications
systems. • David Furrer, ASM president, Pratt & Whitney,
Additional speakers, along with their companies and opportunities for materials modeling and data analytics
presentation topics, are as follows: • Christian Moreau, Concordia Institute for Aerospace Design
• Shalaka Shinde, Stony Brook, segmentation crack formation and Innovation, suspension thermal spraying: innovations and
dynamics in atmospheric plasma spraying coatings applications
• Edward Gildersleeve, Stony Brook, effect of geometry on • Andrew Ang, SEAM (Surface Engineering for Advanced
durability of plasma sprayed thermal barrier coatings Materials), turning science into products - coating solutions for
• Brad Lutz, Honeywell, next generation low thermal hydraulic components
conductivity thermal barrier coating • Menno Zwetsloot, Flame Spray Technologies, eGun™,
• Chin Ma, Curtiss-Wright, development of durable and ethanol based liquid fueled-high-velocity oxyfuel new sustainable
affordable thermal barrier coating with low thermal conductivity fuel, new opportunities and markets
superiority • Bill Jarosinski, Praxair, advancing clearance control coatings
• Ben Nagaraj, GE, evolution of thermal sprayed thermal for next generation engines.
barrier coating systems for aircraft gas turbine applications Attending this symposium offers an opportunity to network
• Jim Harrison, CWST, the application of using laser peening with industry leaders as they deliver the latest coatings research
as a tool to repair aircraft structure for sustainment and life related to the aerospace industry. For more information or to
extension register, visit thermalspray.org/itsa-annual-meeting.
Structural
Welding Code —
Steel
Oseir
Oseir.com / +358-40-7736311
Brian Hazel
Technical Fellow
Coatings in Materials and Process
Engineering Group Pratt & Whitney
(P&W)
Covering the latest technology in: Mr. Brian Hazel has 19 years of experience in gas turbine
material development including work in TBCs, EBCs, bond
l Aerospace Repair
coatings, corrosion resistant coatings, and single crystal
l High Temperature Coatings superalloys. Mr. Hazel has a M.S. in Materials Science and
Engineering from The Ohio State University. He has over 40
l Wear Resistant & Clearance Control patents in the area of high temperature coatings with emphasis
Coatings on TBCs, EBCs, and corrosion resistant systems. Mr. Hazel was
or will be a co-chair for the 2017 thermal Spray of Suspensions
Network with industry leaders as they and Solutions Symposium, 2018 TBC V conference in Irsee,
Germany, 2019 thermal Spray of Suspensions Solutions and
deliver the latest coatings research related EBCs Symposium, and will be the chair of the 2022 TBC VI
to the aerospace industry. conference in Irsee, Germany.
LINCOLN ELECTRIC
Cleveland, OH
Mr. Thomas Brown
ASSOCIATE MEMBER BECOME A
thomas_brown@lincolnelectric.com ORGANIZATIONS MEMBER OF THE
216.383.2951 | lincolnelectric.com
ADVANCED MATERIALS AND
TECHNOLOGY SERVICES INC.
LINEAGE ALLOYS Simi Valley, CA
Baytown, TX Dr. Robert Gansert | rgansert@adv-mts.com
Mr. Jean-Marc Tetevuide 805.433.5251 | adv-mts.com
jtetevuide@lineagealloysllc.com
281.426.5535 | lineagealloys.com Your company should join the
MASON GLOBAL MANAGEMENT LLC International Thermal Spray
Killingworth, CT Association (ITSA) now!
METALLISATION LTD. Mr. Richard P. Mason
Dudley West Midlands, United Kingdom rmason@masonglobalmanagementllc.com
Mr. Stuart Milton | sales@metallisation.com ITSA is now a Standing Committee of
724.554.9439 | masonglobalmanagementllc.com
+44.1384.252464 | metallisation.com the American Welding Society
expanding the benefits of company
STATE UNIVERSITY OF NEW YORK benefits. As a company-member
NORTH AMERICAN HÖGANÄS AT STONY BROOK professional industrial association,
Hollsopple, PA Stony Brook, NY
Mr. Andy Hoffman | andy.hoffman@nah.com our mission is dedicated to expanding
Prof. Sanjay Sampath | ssampath@ms.cc.sunysb.edu
814.361.6875 | hoganas.com 631.632.8480 | ctsr-sunysb.org the use of thermal spray technologies
for the benefit of industry and society.
OERLIKON METCO (US) INC. STRONGHOLD COATING SYSTEMS ITSA members invite your company
Westbury, NY Franklin, OH
Ms. Karen Sender | karen.sender@oerlikon.com Mr. Larry Grimenstein | strongholdone@cs.com
to join us in this endeavor.
516.334.1300 | oerlikon.com/metco 937.704.4020 | strongholdone.com