Research Progress of Cold Sprayed Ni and Ni-Based Composite Coatings: A Review
LI Wenya1(), ZHANG Zhengmao1, XU Yaxin1, SONG Zhiguo2, YIN Shuo3
1.Shaanxi Key Laboratory of Friction Welding Technologies, State Key Laboratory of Solidification Processing, Northwestern Polytechnical University, Xi'an 710072, China 2.Department of Intelligent Equipment, Changzhou College of Information Technology, Changzhou 213164, China 3.Department of Mechanical and Manufacturing Engineering, Trinity College Dublin, Dublin, Ireland
Cite this article:
LI Wenya, ZHANG Zhengmao, XU Yaxin, SONG Zhiguo, YIN Shuo. Research Progress of Cold Sprayed Ni and Ni-Based Composite Coatings: A Review. Acta Metall Sin, 2022, 58(1): 1-16.
Nickel and its alloys have good corrosion and high-temperature oxidation resistance. Cold-spraying (CS) can be applied to Ni and Ni-based composite coatings with good corrosion resistance, due to its advantages of low heat input, dense microstructure, high deposition efficiency, and fast deposition rate, etc. In terms of the open publications, this study summarized the prediction of the critical and particle velocities of Ni-powder particles during CS and then analyzed its deposition characteristics and bonding mechanisms; the property improvement of cold-sprayed Ni and Ni-based composite coatings can be achieved by adjusting the nozzle, powder, and gas parameters; CS combined with laser processing, shot peening, hot rolling, and other technologies can further improve the coating quality; the addition of ceramic particles can increase the strength and corrosion resistance of Ni and Ni-based composite coatings. Finally, several expectations for the widespread application of cold-sprayed Ni and Ni-based composite coatings were presented.
Fund: National Natural Science Foundation of China(52061135101);Research Fund of the State Key Laboratory of Solidification Processing (NPU), China(2021-TZ-01);Open Research Fund of the State Key Laboratory of Solidification Processing (NPU), China(SKLSP-202011)
About author: LI Wenya, professor, Tel: (029)88495226, E-mail: liwy@nwpu.edu.cn
Fig.1 Schematic diagram of cold spray system and principle[6]
Fig.2 Critical velocities estimated by the equation (Eq.(1)), and the finite element analysis value (FEA) and experimental measurement value (Exp.) of Cu and Al (vcr—critical velocity)[28]
Fig.3 The relationship between critical velocity, particle impact velocity and particle size (νimpact—particle impact velocity, DE—deposition efficiency)[29]
Fig.4 Coefficients of restitution for Al, Ni, Cu, and Zn (The coefficient of restitution is equal to zero above the critical velocity)[36]
Method
Value / (m·s-1)
Pros and cons
Numerical simulation
576 (Ni/Cu)[28]
Poor accuracy;
620-630 (Ni/Ni)[30]
convenient;
fast and economical
Deposition efficiency
582 (Ni/Cu)[35]
Moderate accuracy and experiment cost;
unable to consider the influence of factors such as particle size in detail
Single particle measurement
512 (Ni/Cu)[35]
The accuracy is the highest;
650-660 (Ni/Ni)[36]
the influence of factors such as size and oxide film can be considered
Table 1 The critical velocities of Ni particles measured by different methods and their respective pros and cons[28,30,35,36]
Fig.5 TEM image of cold sprayed Ni coating (Particle-particle boundary is marked with arrow)[48]
Fig.6 EBSD characterizations of Ni coating section (N2; 600oC; 3.0 MPa)[49]
Fig.7 Schematics of dynamic recrystallization process (a-e)[49]
Fig.8 Cross-sectional SEM images of the coating at different powder preheating temperatures[60]
Fig.9 Nitrogen deposition efficiency of different metals at different temperatures[62]
Fig.10 The deposition efficiency of cold sprayed Ni coating varies with the spraying angle (The inset at the upper left shows the set of the spraying angle)[63]
Fig.11 The temperature evolution of a single Ni particle deposited on a Cu substrate with the substrate temperature of 25oC, 200oC, and 400oC[67]
Fig.12 Inverse pole figures (IPFs) (a, c) and image quality (IQ) maps (b, d) of the cross section of cold sprayed Ni coating annealed at 400oC (a, b) and 600oC (c, d) for 1 h[69]
Powder/substrate
Preparation condition
Main result
Ref.
Powder: GA-Ni with an average particle size of 35 μm;
substrate: grit blasted low carbon steel
N2; 2.5 MPa; 600oC
Powder preheating temperature (oC):
300, 400, 500, 600
500oC: (274 ± 19) HV0.1, DE: 95%
600oC: (278 ± 15) HV0.1, DE: 90%
[60]
Powder: 26-44 μm GA-Ni;
substrate: grit blasted low carbon steel
N2; 2.5 MPa; 600oC
He; 1.5 MPa; 600oC
N2: 275 HV0.1, DE: 90%
He: 313 HV0.1, DE: 20%
[31]
Powder: 20-30 nm GA-Ni;
substrate: grit blasted Al
He; 1.7 MPa; 25oC
(605 ± 13) HV300g
[45]
Powder: GA-Ni and E-Ni with an average particle size of 34 and 31 μm;
substrate: 1Cr18Ni9 stainless steel
N2; 2.8 MPa; 400oC
GA-Ni: undeposited
E-Ni : (605 ± 13) HV0.3, DE:73%
[24]
Powder: E-Ni with an average particle size of 34 μm;
substrate: grit blasted 410 stainless steel
N2; 2.8 MPa;
gas temperature (oC): 350, 400, 450
350oC: 153 HV0.3, DE: 43.4%
400oC: 194 HV0.3, DE: 73.3%
450oC: 201 HV0.3, DE: 79.7%
[63]
Powder: 10-45 μm GA-Ni
substrate: Al; the surface treatments are polish, ground, grit-blast (2.5 μm), and grit-blast (6.5 μm)
Compressed air; 2.5 MPa; 600oC
Bonding strength: 30 MPa;
25 MPa; 15 MPa; 18 MPa
[66]
Powder: 20-40 μm GA-Ni
substrate: grit blasted low carbon steel
N2; 3.6 MPa; 700oC
heat treatment temperature: 600oC
As-sprayed: 238 HV0.3
Heat-treated: 124 HV0.3
[71]
Table 2 Main results of existing literature on cold sprayed Ni coatings[24,31,45,60,63,66,71]
Fig.13 Cross-sectional OM image of 50Ni-50Ti coating[86]
Powder/substrate
Preparation
condition
Main result
Ref.
Powder 1: 35-87 μm Ni-coated Fe-9.6%Si-5.4%Al
(FeSiAl 62%)
powder 2: 28-58 μm; FeSiAl 60%;
substrate: stainless steel
Compressed air;
2.6 MPa, 550oC;
2.6 MPa, 620oC;
3.0 MPa, 620oC;
3.0 MPa, 650oC
Hardness (HV0.1):
powder 1: 350, 340, 330, 335
powder 2: 280, 275, 273, 269
[87]
Powder: NiCra;
NiCr + 50 Al2O3b;
NiCr + 30WC-Co-Crc
substrate: carbon steel
N2; 700oC; 3.6 MPaa,
3.9 MPab,
3.7 MPac
Hardness: 238 HV0.3a;
398 HV0.3b;
340 HV0.3c
[71]
Powder: 50Ni-50Ti
substrate: carbon steel
Compressed air;
2.7 MPa;
510oC
Coating thickness: 20-30 μm
hardness: (224.7 ± 20.9) HV0.2
[86]
Powder: Ni-20Cr
substrate: SA 516 boiler steel
Compressed air;
1.9 MPa;
450oC
Coating thickness: (250 ± 12) μm
hardness: 586 HV
[79]
Powder: Ni-50Cr
substrate: Superni 75
N2;
3.0 MPa;
600oC
Coating thickness: 298 μm
porosity: 0.875%
hardness: 533.5 HV
[80]
Powder 1: Diamalloy 1005 alloy;
powder 2: Diamalloy 1060 alloy
substrate: carbon steel
N2;
4.0 MPa;
800oC;
spraying distance: 40 mm
Powder 1:
coating thickness: (497 ± 39) μm
porosity: 0.21% ± 0.1%
hardness: (6.4 ± 0.5) GPa
powder 2:
coating thickness: (346 ± 23) μm
Porosity: 1.5% ± 0.2%
hardness: (5.7 ± 1.2) GPa
[85]
Table 3 Results of some cold sprayed nickel-based composite coatings[71,79,80,85-87]
Fig.14 SEM surface morphology of Ni-Al2O3 composite coating after spraying[93]
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