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IN718 Cold Gas Repair Spray of Large Cavities—Microstructure and Residual Stresses

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Book cover Proceedings of the 10th International Symposium on Superalloy 718 and Derivatives (TMS 2023)

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Abstract

Cold gas spray is an established process for coating substrates with similar or dissimilar materials. By use of a high-pressure process gas stream, solid particles are accelerated onto a substrate at supersonic velocities. The method is particularly suited for repair applications since neither structural changes nor oxidation occur during the process. To investigate the suitability of the cold gas spray process for the repair of major defects with up to 4 mm depth in Inconel 718 components, sample geometries were manufactured, containing tapered cavities. The specimen cavities were filled with Inconel 718 particles by a cold gas spray process. Non-destructive high-resolution neutron diffraction experiments were performed by use of the SALSA instrument at the Institut Laue-Langevin (ILL) to evaluate the local residual stress state in the as-sprayed condition. 2D maps of the residual stress distribution over the cross-sectional area of the filled cavities were determined. The results indicate compressive residual stresses within the filled process zone. Metallographic examinations show a good bonding between the repair filling and the substrate as well as strongly deformed particles within the repaired region. The latter indicates significant plastic deformation during cold gas spray, which is also in good agreement with increased diffraction line width from the neutron diffraction analyses in the filled process zone compared to the surrounding substrate.

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Acknowledgements

This project was funded by the German Research Foundation (DFG) through the project 452606919. The authors are grateful to the Institut Laue-Langevin for granting beamtime [31] at the SALSA instrument and for their support. Special thanks are given to Dr. Daniel Schliephake from IAM-WK at KIT for his support and SEM imaging.

Author information

Authors and Affiliations

  1. Institute for Applied Materials (IAM-WK), Karlsruhe Institute of Technology (KIT), Engelbert-Arnold-Str. 4, Karlsruhe, 76131, Germany

    Florian Lang & Jens Gibmeier

  2. Institute of Energy and Climate Research (IEK-1), Forschungszentrum Jülich GmbH, Wilhelm-Johnen-Strasse, Jülich, 52425, Germany

    Johannes-Christian Schmitt, Jochen Fiebig & Robert Vassen

  3. Institut Laue-Langevin (ILL), 71 Avenue des Martyrs, Grenoble, 38000, France

    Sandra Cabeza & Thilo Pirling

Authors
  1. Florian Lang
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  2. Johannes-Christian Schmitt
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  3. Sandra Cabeza
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  4. Thilo Pirling
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  5. Jochen Fiebig
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  6. Robert Vassen
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  7. Jens Gibmeier
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Contributions

Florian Lang: Conceptualisation, Formal analysis, Data curation, Writing—original draft, Writing—review & editing, Visualisation. Johannes-Christian Schmitt: Resources, Writing—review & editing. Sandra Cabeza: Investigation, Resources, Writing—review & editing. Thilo Pirling: Investigation, Resources, Writing—review & editing. Jochen Fiebig: Resources, Writing—review & editing. Robert Vassen: Resources, Project administration, Funding acquisition, Writing—review & editing. Jens Gibmeier: Resources, Supervision, Project administration, Funding acquisition, Writing—review & editing.

Corresponding author

Correspondence to Florian Lang .

Editor information

Editors and Affiliations

  1. General Electric, Cincinnati, OH, USA

    Eric A. Ott

  2. University West, Trollhättan, Sweden

    Joel Andersson

  3. National Energy Technology Laboratory, Albany, OR, USA

    Chantal Sudbrack

  4. Central Iron and Steel Research Institute, Beijing, China

    Zhongnan Bi

  5. ATI Specialty Materials, Monroe, NC, USA

    Kevin Bockenstedt

  6. Wyman Gordon/PPC, Houston, TX, USA

    Ian Dempster

  7. Haynes International, Kokomo, IN, USA

    Michael Fahrmann

  8. National Energy Technology Laboratory, Albany, OR, USA

    Paul Jablonski

  9. Oak Ridge National Laboratory, Oak Ridge, TN, USA

    Michael Kirka

  10. West Virginia University, Morgantown, WV, USA

    Xingbo Liu

  11. Honda R&D Co., Ltd., Wakō, Saitama, Japan

    Daisuke Nagahama

  12. NASA Glenn Research Center, Cleveland, OH, USA

    Tim Smith

  13. Montanuniversität Leoben, Leoben, Austria

    Martin Stockinger

  14. The University of Arizona, Tucson, AZ, USA

    Andrew Wessman

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Lang, F. et al. (2023). IN718 Cold Gas Repair Spray of Large Cavities—Microstructure and Residual Stresses. In: Ott, E.A., et al. Proceedings of the 10th International Symposium on Superalloy 718 and Derivatives. TMS 2023. The Minerals, Metals & Materials Series. Springer, Cham. https://doi.org/10.1007/978-3-031-27447-3_44

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