Cold Spray Impact Conditions for the Deposition of High-Performance Iron-Based Metallic Glass

This study investigates the feasibility of cold spraying amorphous iron-based coatings. Splats tests of cold-sprayed SAM1651 (Fe₄₈Mo₁₄Cr₁₅Y₂C₁₅B₆ at.%) particles impacting a mild steel substrate were performed using varying gas temperatures, gas pressures and particle diameters. Specimen inspection by scanning electron microscopy revealed splat morphologies that varied from well-adhered particles to substrate craters formed by rebounded particles. A finite element model is used to determine the impact temperatures and velocities of adhered particles, as well as those forming rebound craters, and a temperature/velocity window of successful particle deposition is empirically generated to provide a framework for ongoing work on the formation of cold-sprayed SAM1651 coatings. The results indicate that the unique process characteristics of cold spray offer a promising means for the formation of metallic glass coatings that successfully retain the amorphous structure and superior corrosion and wear resistant properties of the feedstock powder.