Properties of aluminum coatings of cold gas-dynamic spraying at corrosion damage zones of 1163RDTV alloy products

Metallurgy and Material Science

Material science


Lapaev A. V.1*, Ryashin N. S.2**, Fomin V. M.2***, Shikalov V. S.2****

1. Western Siberian Center for the Certification of Air Transport Objects, 2a, Novaya Zarya str., Novosibirsk, 630084, Russia
2. Federal State Budgetary Institute of Science Khristianovich Institute of Theoretical and Applied Mechanics Siberian Branch of the Russian Academy of Sciences, 4/1, Institutskaya str., Novosibirsk, 630090, Russia



Cold gas-dynamic spraying is a method for coating process, creation of 3D objects and new materials from powder metals, alloys, composites and powder mixtures. The method was developed based on cognominal physical phenomenon, discovered at the Institute of Theoretical and Applied Mechanics named after S.A. Khristianovich of Siberian branch of the Russian academy of sciences in the early 1980s. Nozzle assembly and a heater are fixed as a part of the cold gas-dynamic spraying test bench based on the industrial robot KR 16-2 in dust-noise proof chamber. While spraying the powder particles are accelerated by the gas flow to the velocities of 400-1200 m/s and form the coating without melting. In a number of works of domestic and foreign researchers the possibility of metallic objects recovery by this method is demonstrated, whereby the study of coatings and materials obtained by this method presents an undoubted scientific and practical interest.

The presented article studies the properties of aluminum coatings formed by the cold gas-dynamic spraying method at corrosion damage zones of the substrates from 1163RDTV structural alloy.

At the first stage of work corrosion damages in the form of surface corrosion of the plates from the 1163RDT alloy were simulated. Then they were recovered by the cold gas-dynamic spraying coatings from ASD-1 aluminum powder. The average measured size of the ASD-1 powder particles was 27 mcm.

Experimental dependencies of porosity and micro-hardness of these coatings and oxygen content in them from deceleration temperature while spraying were obtained. These dependencies allowed sel ect the better coating process mode for performance characteristics recovery of structural elements with corrosion damage.

During the experiments of the second stage the samples recovered by the cold gas-dynamic spraying coatings from the 1163RDTV alloy were tested on tensile strength while static loading. Experimental deformation and fatigue endurance curves were obtained. Due to the low porosity and micro-hardness of the cold gas-dynamic spraying coatings, applied at T0 = 200°C, the samples with corrosion zones recovered by these coatings were selected for static and fatigue stretching tests. The obtained experimental results analysis revealed that with the considered coating process mode the full static hardness characteristics recovery did not occur. Nonetheless, an A1 recovery by the cold gas-dynamic spraying coating from 1163RDTV alloy increases the sample static hardness characteristics in the elastic region of the deformation curve. The fatigue tests revealed the effect of the stress concentrator on fatigue strength, which should be accounted while cold gas-dynamic spraying application for recovering corroded structural elements.

At the final stage of the work, a coating fr om ASD-1 was formed on the TU-154 stringer fragment (an alloy of B95 series). It demonstrates the ability of applying these coatings on the fuselage frame elements.

The results of the presented work demonstrate the high potential of the cold gas-dynamic spraying method in solving the problems of aircraft construction elements recovery and repair.


corrosion, aircraft structures recovery, cold gas-dynamic spraying, aluminum coating, porosity, elemental composition, micro-hardness, strength, fatigue


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