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Optimization of cold spray coating parameters using RSM for reducing the porosity level of AA2024/Al2O3 coating on AZ31B magnesium alloy
https://orcid.org/http://orcid.org/0000-0002-8926-4103
The AZ31B magnesium (Mg) alloy is increasingly finding applications in the aerospace and automotive industries due to its high strength to weight ratio, lower density and good castability. However, the inferior corrosion resistance of these alloys restricts its employability in many engineering applications. To overcome this issue, the Mg alloy is are coated with AA2024 alloy/Al2O3 coating deposited using cold spay coating (CS) process. The minimum level of porosity is important for the superior performance characteristics of these coatings such as hardness and corrosion resistance. The Al alloy coatings when deposited on Mg alloys are susceptible to the formation of porosities. The porosity level can be controlled when coated using the optimum level of processing parameter. So, the main objective of this investigation is to optimize the CS coating parameters for minimizing the porosity level in AA20224/Al2O3 coating deposited on A31B Mg alloy. The CS coating parameters, such as temperature (oC), stand-off distance (mm), and powder feed rate (g/min), were optimised using response surface methodology (RSM). The design expert software was employed to generate the 3D response surfaces and regression-based porosity prediction model. The porosity prediction models were validated statistically using analysis of variance (ANOVA). The effect of cold spray processing parameters on the porosity level of an AA20224/Al2O3 coating deposited on an AZ31B Mg alloy was analysed using 3D response surfaces. The results showed that the AA20224/Al2O3 coating deposited on AZ31B Mg alloy exhibited the minimum porosity level of 2.0 vol% (actual) and 2.32 vol% (predicted) when cold sprayed using a temperature of 520oC, stand-off distance of 12 mm, and a powder feeding rate of 22 g/min. The regression-based porosity prediction model accurately predicted the porosity (vol%) level of AA2024/Al2O3 coating deposited on AZ31B Mg alloy with less than 7.5% error and 95% confidence level. The RSM results predicted porosity level of 1.845 vol% for AA20224/Al2O3 coating cold sprayed on AZ31B Mg alloy using a temperature of 527.77oC, stand-off distance of 9.59 mm, and a powder feeding rate of 22.58 g/min. The ANOVA results revealed that the deposition temperature has a greater effect on the porosity level of cold-sprayed AA20224/Al2O3 coating, followed by stand-off distance and powder feeding rate.
Optimization of cold spray coating parameters using RSM for reducing the porosity level of AA2024/Al2O3 coating on AZ31B magnesium alloy
https://orcid.org/http://orcid.org/0000-0002-8926-4103
The AZ31B magnesium (Mg) alloy is increasingly finding applications in the aerospace and automotive industries due to its high strength to weight ratio, lower density and good castability. However, the inferior corrosion resistance of these alloys restricts its employability in many engineering applications. To overcome this issue, the Mg alloy is are coated with AA2024 alloy/Al2O3 coating deposited using cold spay coating (CS) process. The minimum level of porosity is important for the superior performance characteristics of these coatings such as hardness and corrosion resistance. The Al alloy coatings when deposited on Mg alloys are susceptible to the formation of porosities. The porosity level can be controlled when coated using the optimum level of processing parameter. So, the main objective of this investigation is to optimize the CS coating parameters for minimizing the porosity level in AA20224/Al2O3 coating deposited on A31B Mg alloy. The CS coating parameters, such as temperature (oC), stand-off distance (mm), and powder feed rate (g/min), were optimised using response surface methodology (RSM). The design expert software was employed to generate the 3D response surfaces and regression-based porosity prediction model. The porosity prediction models were validated statistically using analysis of variance (ANOVA). The effect of cold spray processing parameters on the porosity level of an AA20224/Al2O3 coating deposited on an AZ31B Mg alloy was analysed using 3D response surfaces. The results showed that the AA20224/Al2O3 coating deposited on AZ31B Mg alloy exhibited the minimum porosity level of 2.0 vol% (actual) and 2.32 vol% (predicted) when cold sprayed using a temperature of 520oC, stand-off distance of 12 mm, and a powder feeding rate of 22 g/min. The regression-based porosity prediction model accurately predicted the porosity (vol%) level of AA2024/Al2O3 coating deposited on AZ31B Mg alloy with less than 7.5% error and 95% confidence level. The RSM results predicted porosity level of 1.845 vol% for AA20224/Al2O3 coating cold sprayed on AZ31B Mg alloy using a temperature of 527.77oC, stand-off distance of 9.59 mm, and a powder feeding rate of 22.58 g/min. The ANOVA results revealed that the deposition temperature has a greater effect on the porosity level of cold-sprayed AA20224/Al2O3 coating, followed by stand-off distance and powder feeding rate.
Optimization of cold spray coating parameters using RSM for reducing the porosity level of AA2024/Al2O3 coating on AZ31B magnesium alloy
https://orcid.org/http://orcid.org/0000-0002-8926-4103
The AZ31B magnesium (Mg) alloy is increasingly finding applications in the aerospace and automotive industries due to its high strength to weight ratio, lower density and good castability. However, the inferior corrosion resistance of these alloys restricts its employability in many engineering applications. To overcome this issue, the Mg alloy is are coated with AA2024 alloy/Al2O3 coating deposited using cold spay coating (CS) process. The minimum level of porosity is important for the superior performance characteristics of these coatings such as hardness and corrosion resistance. The Al alloy coatings when deposited on Mg alloys are susceptible to the formation of porosities. The porosity level can be controlled when coated using the optimum level of processing parameter. So, the main objective of this investigation is to optimize the CS coating parameters for minimizing the porosity level in AA20224/Al2O3 coating deposited on A31B Mg alloy. The CS coating parameters, such as temperature (oC), stand-off distance (mm), and powder feed rate (g/min), were optimised using response surface methodology (RSM). The design expert software was employed to generate the 3D response surfaces and regression-based porosity prediction model. The porosity prediction models were validated statistically using analysis of variance (ANOVA). The effect of cold spray processing parameters on the porosity level of an AA20224/Al2O3 coating deposited on an AZ31B Mg alloy was analysed using 3D response surfaces. The results showed that the AA20224/Al2O3 coating deposited on AZ31B Mg alloy exhibited the minimum porosity level of 2.0 vol% (actual) and 2.32 vol% (predicted) when cold sprayed using a temperature of 520oC, stand-off distance of 12 mm, and a powder feeding rate of 22 g/min. The regression-based porosity prediction model accurately predicted the porosity (vol%) level of AA2024/Al2O3 coating deposited on AZ31B Mg alloy with less than 7.5% error and 95% confidence level. The RSM results predicted porosity level of 1.845 vol% for AA20224/Al2O3 coating cold sprayed on AZ31B Mg alloy using a temperature of 527.77oC, stand-off distance of 9.59 mm, and a powder feeding rate of 22.58 g/min. The ANOVA results revealed that the deposition temperature has a greater effect on the porosity level of cold-sprayed AA20224/Al2O3 coating, followed by stand-off distance and powder feeding rate.
Optimization of cold spray coating parameters using RSM for reducing the porosity level of AA2024/Al2O3 coating on AZ31B magnesium alloy
Int J Interact Des Manuf
Ashokkumar, M. (author) / Thirumalaikumarasamy, D. (author) / Sonar, Tushar (author) / Vignesh, P. (author) / Deepak, S. (author)
2025-01-01
15 pages
Article (Journal)
Electronic Resource
English
AZ31B magnesium alloy , AA2024/Al<sub>2</sub>O<sub>3</sub> coating , Cold spray coating , Porosity , Optimization , Response surface methodology Engineering , Materials Engineering , Engineering, general , Engineering Design , Mechanical Engineering , Computer-Aided Engineering (CAD, CAE) and Design , Electronics and Microelectronics, Instrumentation , Industrial Design
Residual stress induced by cold spray coating of magnesium AZ31B extrusion
| British Library Online Contents | 2014