Optimizing Cold Spray Parameters for High Entropy Alloy Coatings Using Taguchi and Box–Behnken Design Approaches for Mechanically Alloyed Powder

The present study focused on optimizing the cold spray (CS) process parameters for depositing Fe 20 Cr 20 Mn 20 Ni 20 Co 20 (Cantor alloy) coatings using mechanically alloyed (MA) powder. A two-step design of experiments approach was employed, beginning with the initial screening of input variables...

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Veröffentlicht in:Journal of thermal spray technology 2024-10, Vol.33 (7), p.2278-2297
Hauptverfasser: Sharma, Deepak, Boruah, Dibakor, Ameen, Ahamed, Bakir, Ali Alperen, Paul, Shiladitya
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Sprache:eng
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Zusammenfassung:The present study focused on optimizing the cold spray (CS) process parameters for depositing Fe 20 Cr 20 Mn 20 Ni 20 Co 20 (Cantor alloy) coatings using mechanically alloyed (MA) powder. A two-step design of experiments approach was employed, beginning with the initial screening of input variables using the L8 Taguchi method, followed by the refinement of process parameters through the Box–Behnken design of experiments. Key performance indicators included deposition efficiency (DE), coating thickness per pass, and microstructural parameters including porosity, cracks, and interfacial defects/delamination. The study identified process gas temperature as the primary factor influencing both DE and thickness per pass. Higher gas temperature and pressure, combined with increased scanning speed, resulted in higher DE. The DE of the MA Cantor alloy powder peaked at around 14-15%, with a deposit density greater than 99% achieved at the highest process gas temperature and pressure (1000 °C and 60 bar, respectively). The average hardness of the optimal CS coating deposited using MA powder was found to be 679 ± 17 HV 0.1 , which is approximately 90% greater than the average hardness reported for CS coatings deposited using atomized powder.
ISSN:1059-9630
1544-1016
DOI:10.1007/s11666-024-01838-9