Bonding features and associated mechanisms in kinetic sprayed titanium coatings

This study aims to explore the bonding features and mechanisms present in kinetic spray coatings of commercially pure titanium (CP-Ti) by linking experimental observations with finite element modeling for the purpose of optimizing the deposition process. The numerically predicted deformation features and interface thermomechanical responses of the particles adequately elucidate the deposition characteristics for different impact conditions. The formation of a porous coating by local bonding at relatively low velocity and of a very dense coating accompanied by interfacial melting at higher velocity resulted from deformation localization at high strain rates due to the relatively higher adiabacity as compared with other materials, which is one of the unique bonding mechanisms in CP-Ti. The enhanced thermal boost-up zone due to thermally accelerated adiabatic shear instability by powder preheating resulted in improved coating properties, and is essential for the optimization of economical coating processes. (C) 2009 Acta Materialia Inc. Published by Elsevier Ltd. All rights reserved.