Mechanical and precorroded fatigue properties of coated aluminium aircraft skin system as function of various thermal spray processes

Abstract

Aluminium coatings deposited on AA2024-T3 by the flame arc, atmospheric plasma and high velocity oxyfuel (HVOF) processes were evaluated using quantitative metallography, microhardness, adhesion, three point bend and conventional fatigue tests as well as fatigue tests on precorroded samples. Comparison of the microstructures, mechanical properties, and the fatigue and precorroded fatigue properties of samples with the three types of thermal spray coating, as well as samples of bare AA2024-T3 and Alclad AA2024-T3, revealed that HVOF is the most promising thermal spray process for the deposition of aluminium coatings, and, in particular, HVOF coatings greatly increase the fatigue and precorroded fatigue lifetimes of the AA2024-T3 substrate.

Keywords

CORROSION IMMERSION TEST THERMAL SPRAYING FLAME SPRAYING PLASMA SPRAYING HIGH VELOCITY OXYFUEL (HVOF)ALUMINIUM

Get full access to this article

View all access options for this article.

References

DAVIS

J. R.

: ‘Corrosion of aluminium and aluminium alloys’ 1999

Metals Park

OH, ASM.

KAUFMAN

J. G.

: ‘Properties of aluminium alloys: tensile, creep, and fatigue data at high and low temperatures’ 1999 Materials Park OH, ASM.

QUETS

J. M.

: ‘High cycle fatigue properties of chrome plated 7075-T73 aluminium and 4340 steel,’ Union Carbide Technical Note No.91–03 1991.

HEDGES

M. K.

NEWBERY

A. P.

and GRANT

P. S.

: Proc. Int. Conf. On ‘Spray deposition and melt atomization’, Bremen, Germany 2000.

GASSOT

JUNQUERA

JEANDIN

GUIPONT

CODDET

VERDY

and GRANSHIRE

: Surf Eng., 2001 17 317.

GREYING

D. J.

SHADLEY

J. R.

and RYBICKI

E. F.

: J. Thermal Spray Technol 1994 3 371.

BARDAL

MOLDE

and EGGEN

T. G.

: Br. Corros. J., 1983, 8 15.

REVUN

S. A.

MURAVIOVA

E. L.

and BALAKIREV

V. F.

: Proc. Int. Conf. on ‘Spray deposition and melt atomization’, Bremen, Germany 2000.

SOBOLEV

V. V.

GUILEMANY

J. M.

and NUTTING

: ‘Analysis of different mechanisms of coating-substrate adhesion in thermal spraying,’ Thermal spray: a united forum for scientific and technological advancesASM Metals Park, OH 1997.

10.

ZAAT

J. M.

: Annu. Rev. Mater. Sci., 1983 13 9.

11.

ROSEBERRY

T. J.

and BOLGER

F. W.

: ‘A plasma flame spray handbook,’ U.S. Department of Commerce, National Technical Information Service Report No. MT-043 1977.

12.

IWAMOTO

MAKIMO

UMESAKI

ENDO

and KOBAYASHI

: Proc. 10th Int. Thermal Spray Conference ASM

Metals Park, OH

1983.

13.

LIN

C. K.

and BERNDT

C. C.

: J. Thermal Spray Technol 1994 3 75.

14.

STEFFENS

H. D.

: Proc. Int. Conf. on ‘Spray deposition and melt atomization’ Bremen, Germany 2000.

15.

BRANDT

O. C.

: J. Thermal Spray Technol., 1995 4 147.

16.

SIEGL

KANTOR

and ADAMEK

: Acta Technol GSA V 2001 46 25.

17.

KRUGER

and KNEPPER

: Proc. Int. Conf. on ‘Spray deposition and melt atomization’, Bremen, Germany 2000.