Characterizations and anisotropy of cold-spraying additive-manufactured copper bulk

doi:10.1016/j.jmst.2018.01.002

Abstract

Abstract:

In this study, thick copper coatings were deposited by cold spraying (CS) as an additive manufacturing (AM) method. The interfacial microstructure evolution and mechanical behavior were investigated for the as-sprayed and annealed conditions. In addition, experiments together with numerical simulations were employed to study the recrystallization in different stages. Finally, the mechanical anisotropy of the CSed deposit was tested for the first time, being important to the applications of CS-AM. Results show that there exist two stages of recrystallization in the spraying and annealing processes. Heat treatment has a significant effect on mechanical properties, i.e., the tensile strength increases by 34.2% while microhardness decreases by 43.6%. The mechanical anisotropy analysis shows that the tensile strengths of different directions are completely different and show some regular changes.

Key words: Cold spraying, Additive manufacturing, Microstructure evolution, Mechanical properties, Anisotropy

Kang Yang, Wenya Li, Xueping Guo, Xiawei Yang, Yaxin Xu. Characterizations and anisotropy of cold-spraying additive-manufactured copper bulk[J]. J. Mater. Sci. Technol., 2018, 34(9): 1570-1579.

Figures/Tables 15

Fig 1. (a) SEM micrograph of the used copper powder, (b) powder size distribution and (c) cross-sectional OM micrograph of copper particles.

Fig. 2. Details of tensile specimen (Unit: mm).

Fig. 3. Schematic diagram of the Eulerian symmetric model of (a) particle impact, (b) meshing in a resolution of mesh size being 1/100dp [41,42].

Fig. 4. (a) Sketch of the single pass model and (b) the meshing and particle arrangement [41,42].

Fig. 5. Cross-sectional OM microstructure of CSed copper bulks (a) before and (b) after heat treatment.

Fig. 6. EBSD maps and inverse pole figures of the cross-sectional copper bulks (a) before and (b) after heat treatment. Noting that the figure in lower right corner of (a) shows the corresponding ‘band contrast’.

Fig. 7. (a) Grain size distributions and (b) misorientation distributions of the cross-sectional copper bulks before and after heat treatment.

Fig. 8. Impact information between two copper particles: the effective plastic strain (PEEQ) and temperature (TEMP).

Fig. 9. PEEQ and TEMP after multi-particles impacting.

Fig. 10. Vickers microhardness of the as-sprayed and annealed copper bulks.

Fig. 11. Tensile strength of the as-sprayed and annealed copper bulks.

Fig. 12. SEM micrographs of the fracture surfaces of the tensile samples: (a) as-sprayed and (b) annealed.

Fig. 13. Anisotropy of tensile strength.

Fig. 14. Schematic diagram of the particle velocity near the interface between passes.

Fig. 15. SEM micrographs of the fracture surfaces of the tensile samples in different directions: (a) 0°, (b) 30°, (c) 60° and (d) 90°.

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