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Title: Small Fatigue Crack Growth Mechanisms and Interfacial Stability in Cold-Spray 6061 Aluminum Alloys and Coatings

Abstract

Cold-spray-processed aluminum alloys have static mechanical properties superior to those of aerospace cast alloys, and similar to those of their wrought counterparts, making them good candidates for structural applications. However, their broad and confident use relies upon systematic fatigue crack growth studies to investigate and demonstrate the materials' performance in critical high-integrity components. In this work, the fatigue crack growth behavior in early stages (small crack growth regime) was investigated for cold-spray processed 6061 aluminum alloys and coatings, at stress ratio R = 0.1, in room temperature laboratory air. The effects of the characteristic microstructure and initial flaw size on the fatigue crack growth response were systematically examined, and the crack growth mechanisms at the microstructural scale were established and compared to those of long cracks. The mechanical interfacial stability of coatings was examined in cold-spray 6061-rolled 6061-T6 couples. An original method of quantifying the deposition-substrate interfacial strength, and correlating it to the response under cyclic loading via crack-interface stability maps, was developed. The proposed methodology is based on combined scratch testing and fracture mechanics formulations, and failure at the coating-substrate interface can be predicted for any crack growth scenario under cyclic loading. The method can be broadly used formore » the design and optimization of cold-spray and other coatings, as well as in structural repair.« less

Authors:
 [1];  [1];  [2];  [1];  [3]
  1. Worcester Polytechnic Inst., Worcester, MA (United States)
  2. U.S. Army Research Lab., Aberdeen, MD (United States)
  3. Argonne National Lab. (ANL), Argonne, IL (United States)
Publication Date:
Research Org.:
Argonne National Lab. (ANL), Argonne, IL (United States)
Sponsoring Org.:
Worcester Polytechnic Institute; USDOE
OSTI Identifier:
1501861
Grant/Contract Number:  
AC02-06CH11357
Resource Type:
Accepted Manuscript
Journal Name:
Metallurgical and Materials Transactions. A, Physical Metallurgy and Materials Science
Additional Journal Information:
Journal Volume: 49; Journal Issue: 12; Journal ID: ISSN 1073-5623
Publisher:
ASM International
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE; 42 ENGINEERING; aluminum alloys; cold-spray; fatigue

Citation Formats

Gavras, Anastasios G., Lados, Diana A., Champagne, Victor K., Warren, Robert J., and Singh, Dileep. Small Fatigue Crack Growth Mechanisms and Interfacial Stability in Cold-Spray 6061 Aluminum Alloys and Coatings. United States: N. p., 2018. Web. doi:10.1007/s11661-018-4929-0.
Gavras, Anastasios G., Lados, Diana A., Champagne, Victor K., Warren, Robert J., & Singh, Dileep. Small Fatigue Crack Growth Mechanisms and Interfacial Stability in Cold-Spray 6061 Aluminum Alloys and Coatings. United States. doi:10.1007/s11661-018-4929-0.
Gavras, Anastasios G., Lados, Diana A., Champagne, Victor K., Warren, Robert J., and Singh, Dileep. Mon . "Small Fatigue Crack Growth Mechanisms and Interfacial Stability in Cold-Spray 6061 Aluminum Alloys and Coatings". United States. doi:10.1007/s11661-018-4929-0. https://www.osti.gov/servlets/purl/1501861.
@article{osti_1501861,
title = {Small Fatigue Crack Growth Mechanisms and Interfacial Stability in Cold-Spray 6061 Aluminum Alloys and Coatings},
author = {Gavras, Anastasios G. and Lados, Diana A. and Champagne, Victor K. and Warren, Robert J. and Singh, Dileep},
abstractNote = {Cold-spray-processed aluminum alloys have static mechanical properties superior to those of aerospace cast alloys, and similar to those of their wrought counterparts, making them good candidates for structural applications. However, their broad and confident use relies upon systematic fatigue crack growth studies to investigate and demonstrate the materials' performance in critical high-integrity components. In this work, the fatigue crack growth behavior in early stages (small crack growth regime) was investigated for cold-spray processed 6061 aluminum alloys and coatings, at stress ratio R = 0.1, in room temperature laboratory air. The effects of the characteristic microstructure and initial flaw size on the fatigue crack growth response were systematically examined, and the crack growth mechanisms at the microstructural scale were established and compared to those of long cracks. The mechanical interfacial stability of coatings was examined in cold-spray 6061-rolled 6061-T6 couples. An original method of quantifying the deposition-substrate interfacial strength, and correlating it to the response under cyclic loading via crack-interface stability maps, was developed. The proposed methodology is based on combined scratch testing and fracture mechanics formulations, and failure at the coating-substrate interface can be predicted for any crack growth scenario under cyclic loading. The method can be broadly used for the design and optimization of cold-spray and other coatings, as well as in structural repair.},
doi = {10.1007/s11661-018-4929-0},
journal = {Metallurgical and Materials Transactions. A, Physical Metallurgy and Materials Science},
number = 12,
volume = 49,
place = {United States},
year = {2018},
month = {10}
}

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