Characterization and optimization of cold sprayed nickel- and nickel-based alloys on aluminum and steel substrates for corrosion protection and high temperature applications

摘要

In this thesis the use of nickel and Inconel as coating materials for cold spraying were examined. For this purpose mechanical and physical properties were evaluated. The aim was to qualify and optimize the coating materials and spray parameters for serial production or single item production regarding reproducibility, process safety and efficiency. The following test methods were used to verify the spray parameters and to analyse the coatings: shear strength test, adhesive tensile strength test, hardness, porosity measurement, DE and metallographic screening. Furthermore, a correlation was performed between the shear resistance and the adhesive tensile strength of the applied coatings. Component regeneration and protection coatings against mechanical and chemical stress, e.g. wear and/or corrosion, are fields of application. The materials used have a great potential for thermally stressed components, such as turbine parts or power plant components. In addition for optimization of the mechanical and physical properties a new method has been developed to produce cold sprayed coatings with a maximum porosity of 28%.