A parametric study on residual stresses induced by cold spraying Ti-6Al-4V on Ti-6Al-4V substrates

Wednesday, May 29, 2019: 09:00
Annex Hall/F202 (Pacifico Yokohama)
Mr. Dibakor Boruah, PhD (pursuing) , Coventry University, Coventry, United Kingdom
Dr. Bilal Ahmed, PhD , Coventry University, Coventry, United Kingdom
Dr. Abdul Khadar Syed, PhD , Coventry University, Coventry, United Kingdom
Dr. Tung Lik Lee, PhD , ISIS Neutron Facility, STFC Rutherford Appleton Laboratory, Didcot, United Kingdom
Dr. Saurabh Kabra, PhD , ISIS Neutron Facility, STFC Rutherford Appleton Laboratory, Didcot, United Kingdom
Dr. Philip McNutt, PhD , TWI Ltd, Cambridge, United Kingdom
Dr. Matthew Doré, PhD , TWI Ltd, Cambridge, United Kingdom
Prof. Xiang Zhang, PhD , Coventry University, Coventry, United Kingdom
Cold spray (CS) is a solid-state additive material deposition technique, which has gained attention in the aerospace industry as a potentially viable technology for structural repair of high value parts made of high-strength alloys such as Ti-6Al-4V (Ti-64). The distribution and magnitude of residual stresses that build up in the substrate and deposited materials during cold spraying can influence the mechanical performance, substrate-deposit adhesion, cohesion between deposited layers, and overall integrity of a coating or repair. However, the nature, magnitude and distribution of residual stresses in Ti-6Al-4V/Ti-6Al-4V CS repairs are currently unknown. This study aims to evaluate the effects of geometrical variables (number of CS layers, individual CS layer height, and substrate height), track pattern and post-deposition heat treatment on the magnitude and distribution of residual stresses in cold spray deposit-substrate assemblies. Residual stress profiles were measured experimentally by contour method and neutron diffraction at ENGIN-X, ISIS Neutron Source, UK. An analytical model was developed to predict the through-thickness residual stress distributions which were validated by the experimental measurements.
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