Evaluating the damage tolerant behavior of cold spray repaired aluminum alloys

IF 5.7 2区材料科学 Q1 ENGINEERING, MECHANICAL

International Journal of Fatigue Pub Date : 2024-09-12 DOI:10.1016/j.ijfatigue.2024.108607

Patrick E. Morrison, Krzysztof S. Stopka, John I. Ferguson, Michael D. Sangid

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Abstract

Cold spray presents a promising solution for repair of damaged material within high-value components. However, before employing cold spray for component repair, it is crucial to assess its damage tolerance and durability. This study focuses on evaluating the fatigue behavior of helium-sprayed AA6061 applied to an A356-T6 cast substrate compared to the same specimen geometry made entirely of the A356-T6 material. Fatigue testing was conducted using a marker band schedule to analyze fatigue crack growth rates in the cold spray and substrate materials. To complement the fatigue testing, experimental uncertainties and variabilities were incorporated into a crack growth model using a Monte Carlo approach to probabilistically assess reliability. The results indicate that the AA6061 cold spray material exhibited faster crack growth, resulting in a ∼25% lower life compared to the baseline A356-T6 material. Given the cost effectiveness of the cold spray repair process, it appears to be a viable approach, with the caveats that the residual life is expected to be less than the pristine substrate material and the cold spray interface is prone to delamination during crack impingement.

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评估冷喷修复铝合金的损伤容限行为

冷喷技术为修复高价值部件内的受损材料提供了一种前景广阔的解决方案。不过，在使用冷喷技术修复部件之前，评估其损伤容限和耐久性至关重要。本研究的重点是评估与完全由 A356-T6 材料制成的相同几何形状试样相比，在 A356-T6 铸造基体上喷氦气的 AA6061 的疲劳行为。疲劳测试采用标记带计划来分析冷喷材料和基体材料的疲劳裂纹生长率。作为疲劳测试的补充，使用蒙特卡罗方法将实验不确定性和变异性纳入裂纹增长模型，以从概率上评估可靠性。结果表明，与基准 A356-T6 材料相比，AA6061 冷喷材料的裂纹生长速度更快，导致寿命缩短了 25%。鉴于冷喷修复工艺的成本效益，它似乎是一种可行的方法，但需要注意的是，残余寿命预计低于原始基体材料，而且冷喷界面在裂纹撞击过程中容易分层。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

International Journal of Fatigue 工程技术-材料科学：综合

CiteScore

10.70

自引率

21.70%

发文量

619

审稿时长

58 days

期刊介绍： Typical subjects discussed in International Journal of Fatigue address: Novel fatigue testing and characterization methods (new kinds of fatigue tests, critical evaluation of existing methods, in situ measurement of fatigue degradation, non-contact field measurements) Multiaxial fatigue and complex loading effects of materials and structures, exploring state-of-the-art concepts in degradation under cyclic loading Fatigue in the very high cycle regime, including failure mode transitions from surface to subsurface, effects of surface treatment, processing, and loading conditions Modeling (including degradation processes and related driving forces, multiscale/multi-resolution methods, computational hierarchical and concurrent methods for coupled component and material responses, novel methods for notch root analysis, fracture mechanics, damage mechanics, crack growth kinetics, life prediction and durability, and prediction of stochastic fatigue behavior reflecting microstructure and service conditions) Models for early stages of fatigue crack formation and growth that explicitly consider microstructure and relevant materials science aspects Understanding the influence or manufacturing and processing route on fatigue degradation, and embedding this understanding in more predictive schemes for mitigation and design against fatigue Prognosis and damage state awareness (including sensors, monitoring, methodology, interactive control, accelerated methods, data interpretation) Applications of technologies associated with fatigue and their implications for structural integrity and reliability. This includes issues related to design, operation and maintenance, i.e., life cycle engineering Smart materials and structures that can sense and mitigate fatigue degradation Fatigue of devices and structures at small scales, including effects of process route and surfaces/interfaces.