Journal of Advanced Materials in Engineering

Journal of Advanced Materials in Engineering

Effect of Gas Pressure and Stand-Off Distance on the Properties of Cold Sprayed Zinc on Steel Substrate

Document Type : Original Article

Authors
Mohammad Hadi Khanbabaee Saatloo
Amir Abdollah-Zadeh
Rajab Ali Seraj
Department of Materials Engineering, Faculty of Mining and Materials Engineering, Tarbiat Modares University, Tehran, Iran
10.47176/jame.44.2.1084
Abstract
Introduction and Objectives: The properties of coatings deposited by cold spray depend on the parameters of the process. The aim of this research is to investigate the effect of gas pressure and stand-off distance of cold spray process of zinc on a low carbon steel substrate.
Materials and Methods: In this research, zinc powder was sprayed at pressures of 20 and 30 bar and stand-off distances of 20 and 30 mm. The microstructure of the coatings was investigated using optical and scanning electron microscope and the micro-hardness of the coatings was measured. Then, the selected coating and steel substrate were subjected to polarization corrosion test.
Results: The results showed that increasing the gas pressure from 20 to 30 bar decreased the porosity and increased the micro-hardness due to further deformation. Also, for a constant pressure, the stand-off distance of 20 mm has the lowest porosity and the highest micro-hardness due to the higher temperature of the particles when impact the substrate. The results obtained from the polarization test show that the coating has a sacrificial nature compared to the substrate and reduces the corrosion current density by 48% and corrosion rate by 33% compared to the substrate.
Conclusion: In this study, the effect of gas pressure and stand-off distance of cold spray process of zinc on low carbon steel substrate was investigated. The results showed that increasing the gas pressure from 20 to 30 bar and reducing the stand-off distance from 30 to 20 mm improved porosity and increased coatings micro-hardness. The results of this study can be used to optimize the parameters of the cold spraying of zinc for use in various industries such as automotive, power plants and marine infrastructure.
Keywords
Cold spray
Steel
Zinc
Porosity
Corrosion resistance
Subjects
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Journal of Advanced Materials in Engineering
Volume 44, Issue 2
2025
Pages 37-48

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