Optimization of Grit-Blasting Process Parameters for Production of Dense Coatings on Open Pores Metallic Foam Substrates Using Statistical Methods

摘要

Open pore metallic foam core sandwich panels prepared by thermal spraying of a coating on the foam structures can be used as high-efficiency heat transfer devices due to their high surface area to volume ratio. The structural, mechanical, and physical properties of thermally sprayed skins play a significant role in the performance of the related devices. These properties are mainly controlled by the porosity content, oxide content, adhesion strength, and stiffness of the deposited coating. In this study, the effects of grit-blasting process parameters on the characteristics of the temporary surface created on the metallic foam substrate and on the twin-wire arc-sprayed alloy 625 coating subsequently deposited on the foam were investigated through response surface methodology. Characterization of the prepared surface and sprayed coating was conducted by scanning electron microscopy, roughness measurements, and adhesion testing. Using statistical design of experiments, response surface method, a model was developed to predict the effect of grit-blasting parameters on the surface roughness of the prepared foam and also the porosity content of the sprayed coating. The coating porosity and adhesion strength were found to be determined by the substrate surface roughness, which could be controlled by grit-blasting parameters. Optimization of the grit-blasting parameters was conducted using the fitted model to minimize the porosity content of the coating while maintaining a high adhesion strength.