INTRODUCTION

Cold Spray is an emerging technique which produces high density coatings. The cold spray method is related to thermal spray methods but it has some interesting additional features. In this technique particles (1 to 50 m in diameter) to be coated are carried by a supersonic gas stream through a de Laval nozzle and, finally they, impact on a substrate with high kinetic energy. Due to low gas temperatures (600C) the sprayed material remain in solid state during the whole process. The principles involved in cold spray method are discussed briefly in the paper. This paper demonstrates the successful deposition of commercially available Ni20Cr and Ni50Cr powders on T22 and SA 516 boiler steels. Thick coatings of approximately 250m thickness were obtained on the boiler steels by this technique. The characterization of the coatings was done with the help of Scanning Electron Microscopy (SEM) and Energy Dispersive Spectroscopy (EDS). From the results it has been concluded that the cold spray method could successfully be used for the deposition of coatings on the said steels. In the conventional thermal spraying processes such as flame spraying, arc spraying and plasma spraying, it is important that the material melts completely. With High Velocity Oxy-fuel (HVOF) spraying, a partial melting is sufficient to achieve a high-quality coating. The reason for this is that the particle velocities upon impact on the substrate are considerably higher in HVOF spraying. In the new process, cold spraying, this development towards higher particle velocities with simultaneously reduced and controlled heat input of the spray material has been rigorously continued. Here the gas temperature is well below the melting temperature of the material, so that the particles in the jet no longer melt [1]. A systematic of cold spray coating process is given in Figure. In the cold-spray process, metal powder particles develop into a coating as a result of ballistic impingement on a substrate. In cold-spray, compressed gas (air, nitrogen or helium), at pressures ranging between 1.4 3.4 MPa (200500 psi), but typically around 1.7 MPa (250 psi), flows through a manifold system containing a gas heater and a powder feeder.

The pressurized gas is heated electrically to around 1006000oC then passed through a Lavaltype converging/diverging nozzle until the gas velocities reach supersonic speeds. The powder particles are introduced into the gas stream just in front of the converging section of the nozzle and are accelerated by the expanding gas. The powder feedstock is delivered on the highpressure side of the nozzle by the metering device, which is heated and maintained at the elevated pressure of the manifold. During the supersonic expansion through the Laval nozzle, there is a temperature reduction. Thus, the temperature of the gas stream is always below the melting point of the particulate material, providing coatings developed primarily from particles in the solid state with very little oxidation [2]. Cold Spray Process Features It is a low temperature process, so no bulk particle melting occurs. The composition/ phases of initial phases are retained. Very little oxidation is caused as compared to other spray processes. Eliminates solidification stresses which, enables formation of thicker coatings. Coatings with low defects are obtained by this method. Because of high gas flows involved, high gas consumption is required. If helium is used it increases the cost of coating as it is very expensive unless it is recycled This process is still mainly in research and development stage. Cold spray coatings is a unique technology that allows to fabricate dense, low oxide-content deposits of ductile materials like aluminum, stainless steel, copper, titanium and alloys, but it is limited to ductile materials only, hard and brittle materials like ceramics can not be sprayed in the pure form, but may be applied as composites with a ductile matrix phase. Being a relatively young process considerable R&D efforts are needed to understand and control the process, as well as develop engineered coatings with desired properties for specific applications. The cold spray process is still primarily in the research and development stage and only now becoming commercially available, and has been accepted as a new and novel thermal spray technique mainly in developed countries. The technology has great potential for future research especially with reference to its application to real industrial solution.

LITERATURE REVIEW
The cold spray process was developed in the mid 1980s at the Institute of Theoretical and Applied Mechanica of the Russian Academy of Science in Novosibirsk by A. Papyrin and colleagues [3-7]. They successfully deposited a wide range of pure metals, metal alloys, and composites onto a variety of substrate materials and demonstrated the feasibility of cold spray for various applications. A U.S. patent on the cold spray technology was issued in 1994 [8], and a European one in 1995 [9]. Residual stresses are commonly generated during coating production. Coating performance indicators such as spallation resistance, thermal cycling life and fatigue properties are strongly influenced by residual stresses. A driving force for deboning is normally associated with the relaxation of these stresses [15-17]. The data base of the results will provide useful information to the metallurgists regarding the residual stresses in the coatings and they could select the coating/substrate combination suitable for the particular application based upon the calculated data. Further the project will provide scientific information regarding the effect of residual stresses and other thermal properties on the wear performance of the thermal sprayed coatings, which is a potential area of research in the current times The experimental measurement of residual stresses originating within thick coatings deposited by cold spray process onto solid substrates plays a fundamental role in the preliminary stages of coating design and process parameters optimization. Residual stresses in the coating arise during the thermal spray process and influence significantly the coating quality and substrate performance. In service stresses in the coating systems are caused by the temperature gradients and by the non-uniform plastic deformation due to thermal and mechanical loads. The knowledge about the occurrence and magnitude of residual stresses is an important factor for the performance of subsequent fabrication steps and for the operation lifetime, where residual and load stresses interact [14] The acceptance of thermal spray coatings in many applications depends on the effect of the coating on the fatigue performance of the coated part. One of the factors that influence the fatigue life of cold spray-coated components is the residual stresses in the coating. Therefore, the study of the physical properties of the cold sprayed coatings is a very important topic from both engineering and an economic perspective Since there has been very limited information available in the literature regarding the role of residual stresses on the performance of the cold spray coatings for various applications, there is tremendous potential for filing patents from the investigation. It is anticipated that there is a scope to develop some novel coating compositions for the wear related industrial problems which can be patented. Critical residual stresses can cause failure of coatings in form of delamination and cracking. Tensile residual stresses in the coating reduce component lifetime under dynamic loading since this favours crack formation and propagation, whereas compressive surface stresses increase the fatigue strength. The final residual stress state of thermally sprayed components is superimposed by following individual stress mechanisms during manufacturing [12-13]. Recent reports emphasized that the understanding of the mechanism, measurement and

calculations of residual stresses for thermal sprayed coatings need to be improved, particularly with respect to its effects on the coating performance. Residual stress measurements and calculations would provide a platform for the researchers and academicians for selecting the correct combination for particular application. These studies are crucial for the Long-term stability of the coatings regarding the failure mechanisms in various working conditions. Cold spray is a solid state process and hence produces coatings with many advantageous characteristics. Since high temperature is not involved, it is ideally suitable for spray depositing temperature-sensitive materials such as nanophase and amorphous materials, oxygen-sensitive materials like aluminum, copper and titanium and phase-sensitive materials such as carbide composites. Due to small size of the nozzle (10-15 mm 2) and spray distance (5-25 mm), the spray beam is very small, typically around 5 mm diameter, which translate into precise control over the area of deposition over the substrate surface. Cold spray process works similar to a micro shot peening device and hence the coatings are produced with compressive stresses. Thus, ultra thick (5-50 mm) coatings can be produced without adhesion failure. The high energy-low temperature formation of coating leads to a wrought-like microstructure with near theoretical density values. Most metals are thermodynamically unstable in air and react with oxygen to form an oxide. As the oxidation usually develops as a layer or scale on the surface of the metal or alloy, it can give protection by acting as a barrier that separates the metal from the gas. Further oxidation requires the metal ions and/or oxygen to penetrate across the barrier layer and combine chemically to form new oxide at the scale/gas or scale/metal interface. This process is usually controlled by the rate of diffusion of the reactants across the barrier layer and, hence, is very dependent on temperature, reflecting the exponential relationship between rates of diffusion and temperature. 570C. Thus, for this application at higher temperatures, alloys (usually based on iron, iron nickel or nickel) are designed to develop a slow growing barrier layer at the base of the oxide scale. For instance, a typical gas turbine alloy, based on Ni20wt%Cr, contains sufficient chromium to develop a barrier layer of Cr2O3 at the base of the NiO-rich scale during oxidation at temperatures up to 900C. This oxide layer gives effective protection against further oxidation and metal losses are usually acceptably low. As well as protecting against loss of metal due to chemical oxidation, oxides can also protect against loss of metal due to mechanical damage caused by sliding wear. Indeed, the beneficial effects of oxygen in helping to reduce wear have been recognized for many years. So in this study we are calculating the residual stresses of the air sprayed as well as the oxidized samples.

From the literature it has been concluded that comparatively less work has been done in the field of study of the properties of cold spray coated steels. The proposed investigation will help to establish the science base behind the phenomenon of residual stresses and its likely impact on the service life of the component.

OBJECTIVES
The aim of the present study is to analyze the influence of cold spray procedures on the final characteristics of the coatings. Main objective of cold spray coatings:

To investigate the physical properties of high performance and economical cold spray coatings for industrial use: Aerospace - for repair/refurbishment of space shuttle solid rocket boosters and others, Aircraft industry: repair and retrieval of parts and plate stocks used in aircraft structures . Gas turbine: repair/refurbishment of casings, Petrochemical: corrosion protection coatings etc. The physical properties include micro hardness, roughness and residual stresses. There is not much data available on the residual stresses of coatings so from this study we can prepare a data base of the physical properties of cold spray coatings for which the available literature is rare. To calculate the residual stresses of the air sprayed as well as the oxidized samples of cold spray coatings. The project is mainly focussed on the determination of the physical properties of cold sprayed coatings. cold sprayed Nickel-based alloy coatings are used in a variety of applications such as turbine components, restorative layers for machine parts, bond coats in internal combustion engine cylinders, for corrosion protection of boiler tubes and in numerous other applications requiring wear, high temperature and corrosion resistant surfaces. Determination of residual stresses in thermal spray processes is an important technological aim since the residual stress levels present in the coatings and their sign have a significant effect on coating performance.

METHOLOGY
Two substrate materials were selected for the spraying. The first test material selected was SAE 213 - T22 steel, which is being currently used as boiler tube material at Guru Gobind Singh Super Thermal Power Plant Ropar (Punjab), India. The second test specimen was obtained from Cheema Boilers limited, Ban Majra, Kurali. i.e. SA 516 (Grade 70). This industry is involved in the manufacturing and installation of boiler plants. The composition of the two steels is given in Table 1.

Table 1: Nominal composition of steels

Chemical Composition (wt %) C Mn P S Si Cr Mo Fe

Boiler Steel SAE 213-(T22) SA 516 (Grade 70) 0.27 0.85-1.2. .035 max .035 max 0.13-0.45 Balance

0.15 0.3-0.6 .03 max .03 max 0.5 1.9- 2.0 0.87-1.13 Balance

Specimens with dimensions of approximately 20mmX15mmX5mm were cut from the boiler tubes. The specimens were polished with SiC papers down to 180 grit. Cold spray coatings were deposited on the said steels at ASB Industries, Inc, Barbeton, USA. Two different types of commercially available coating powders were used on the substrates; one was Ni 20Cr powder and other was Ni 50Cr powder. The parameters used during spraying are given in Table 2.

Table 2: Process parameters for the cold spray process

Process Gas Gun Temperature Gun Pressure Process Rate Gas Flow

Helium 400 oC 20.5 bars 150m3/sec 40g/min Nitrogen 4m3/hr 250m

Powder Feed Rate Carrier Gas Flow Rate of Carrier Gas Coating Thickness

As the samples are cold sprayed the Hardness and Roughness of cold sprayed samples is tested. Then the residual stresses are calculated for the air sprayed and oxidized samples and after calculating that the comparison is done.

REFERENCES

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