A viable approach to repair neutron shielding B4C/6061 Al composite sheets through cold spray and hot rolling co-treatment

doi:10.1016/j.jmst.2021.06.085

Abstract

Abstract:

Cold spray (CS) is considered as a new type of repairing technique for restoration or remanufacturing of a wide range of unserviceable engineering components due to its unique ‘cold’ characteristic. In this work, a viable repairing approach i.e. "cold spraying followed by hot rolling post-treatment" was successfully applied to restore defective neutron shielding B₄C/6061 Al composite plates. Scanning electron microscopy (SEM) and electron backscatter diffraction (EBSD) results revealed that the coating-substrate interface is in a good bonding state without micro-cracks. Hot rolling post-treatment resulted in improved microstructure of the as-sprayed deposit with more uniform distribution of B₄C particles in the matrix. Moreover, well bonded splat boundaries and strain free Al grains were evolved in the matrix due to enhanced splat deformation and continuous dynamic recrystallization (CDRX). Three-point bending test results revealed that the strength of the repaired material is at par with the in-service plates. The findings of this work could be considered as a great stride to further extend possible applications of CS for repairing engineering structural components.

Key words: B₄C/6061 Al, Cold spray, Repairing, Three-point bending test

Xiang Qiu, Lu Qi, Jun-rong Tang, Naeem ul Haq Tariq, Ji-qiang Wang, Tian-ying Xiong. A viable approach to repair neutron shielding B₄C/6061 Al composite sheets through cold spray and hot rolling co-treatment[J]. J. Mater. Sci. Technol., 2022, 106: 173-182.

Figures/Tables 10

Fig. 1. Digital images of the as-received B4C/6061Al composite sheet showing a number of fabrication surface defects (a) and high-magnification laser confocal images of the region highlighted by orange trapezium in panel ‘a’ (b).

Fig. 2. Schematic representation of cold spray repairing process.

Fig. 3. SEM images of mechanically blended B4C/6061Al powder at low magnification (a) and high magnification (b). Particle size distribution of 6061 Al (c) and B4C (d) powders, respectively.

Fig. 4. SEM cross-sectional images of as-sprayed (a-c), Rolled-10 (d-f) and Rolled-20 (g-i) samples.

Fig. 5. FSD cross-sectional images of as-sprayed (a), Rolled-10 (b) and Rolled-20 (c) samples. Panel (d), (e) and (f) shows magnified FSD images of the highlighted region in panel ‘a’, ‘b’ and ‘c’ while part of FSD image is overlapped with corresponding IPF map (superimposed on image quality map). Panel (g), (h) and (i) shows close up image of deposit/substrate interfaces in panel ‘d’, ‘e’ and ‘f’.

Fig. 6. Grain size distribution for as-sprayed, Rolled-10 and Rolled-20 B4C/6061 Al composite deposits.

Fig. 7. Kernel average misorientation (KAM) maps of as-sprayed, Rolled-10 and Rolled-20 B4C/6061 Al composite samples.

Fig. 8. XRD pattern of powder mixture, as-sprayed, Rolled-10 and Rolled-20 B4C/6061 Al composite deposits.

Fig. 9. Three point bending load-displacement curve of different samples.

Fig. 10. SEM cross-sectional images of fractured samples at different processing conditions: as-sprayed (a-c), Rolled-10 (d-f) and Rolled-20 (g-i).

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A viable approach to repair neutron shielding B₄C/6061 Al composite sheets through cold spray and hot rolling co-treatment

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