Optimization of Cold Spray Process Inputs to Minimize Porosity and Maximize Hardness of Metal Matrix Composite Coatings on AZ31B Magnesium Alloy

In this investigation, the development of an empirical relationship to determine the porosity and microhardness of the coatings through low-pressure cold-sprayed (LPCS) aluminum alloy/alumina metal matrix composite (MMC) deposit. Spray parameters like temperature, standoff distance (SOD), and powder...

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Bibliographic Details
Published in:Journal of nanomaterials 2022, Vol.2022 (1)
Main Authors: Mohankumar, Ashokkumar, Duraisamy, Thirumalaikumarasamy, Sampathkumar, Deepak, Ranganathan, Sathiyamoorthy, Balachandran, Guruprasad, Kaliyamoorthy, Murugan, Mariappan, Mathanbabu, Mulugeta, Lijalem
Format: Article
Language:English
Subjects:
Alumina
Aluminum alloys
Aluminum base alloys
Aluminum oxide
Coatings
Cold
Cold spraying
Experimentation
Feed rate
Interfacial bonding
Low pressure
Magnesium alloys
Magnesium base alloys
Mathematical models
Metal matrix composites
Microhardness
Nanomaterials
Optimization
Parameters
Plasma
Porosity
Protective coatings
Response surface methodology
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Summary:In this investigation, the development of an empirical relationship to determine the porosity and microhardness of the coatings through low-pressure cold-sprayed (LPCS) aluminum alloy/alumina metal matrix composite (MMC) deposit. Spray parameters like temperature, standoff distance (SOD), and powder feed rate play an essential part in the determination of the coating effectiveness. In this study, 3 variables, 5 levels of central composite rotatable design (CCD) were used to decrease the total count of the experimentation. A mathematical model has been developed to evaluate the porosity and hardness of the coated samples along with LPCS spray parameters, and the model’s applicability was inspected by ANOVA. Utilizing response surface methodology, spray parameter optimization was carried out. The deposit developed by optimal spray parameters produces the lowest surface porosity of 3.31 vol.% and a higher hardness of 137.21 HV compared with other coated samples. It is validated through the response graph. As a result, the optimized parameters for aluminum alloy/alumina metal matrix composite (MMC) coatings via LPCS are 500 degrees Celsius, 10 mm SOD, and 20 grams/min powder feed rate.
ISSN:1687-4110
1687-4129
DOI:10.1155/2022/7900150