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<p>This study systematically investigated the effects of plasma-assisted cold spraying process and gas pressure (3.5-5.0&#xa0;MPa) on the microstructure and properties of 2219 aluminum coatings. The results showed that increasing the gas pressure and introducing a plasma heat source significantly enhanced the coating thickness and improved particle bonding strength. This mechanism is attributed to the synergistic effect of gas pressure-enhanced particle kinetic energy and plasma heat source-induced particle thermal softening. The high temperature (450&#xa0;°C) induced by the plasma heat source causes the decomposition of the Al<sub>2</sub>Cu phase, forming a Cu-depleted zone, as confirmed by the reduced intensity of the Al<sub>2</sub>Cu diffraction peak in XRD analysis. EBSD revealed an increase in dynamic recrystallization rate in the PACS coating, with the average grain size decreasing to 2.391&#xa0;μm. In terms of mechanical properties, the bonding strength of the PACS coating increased to 43.32 at 5.0&#xa0;MPa pressure, and the fracture surface exhibited ductile indentation characteristics, confirming that the plasma heat source promoted local metallurgical bonding. Additionally, the coating hardness increased to 107.98 HV (reaching 80% of the substrate hardness), and the wear rate decreased to 0.59 × 10<sup>−3</sup> mm<sup>3</sup>/(N&#xa0;m), representing an 80% reduction compared to the CS coating under 3.5&#xa0;MPa air pressure. This process overcomes the limitations of traditional cold spraying interface bonding by adjusting gas pressure and introducing a plasma heat source to induce thermal activation and dynamic recrystallization.</p>

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The Effect of Gas Pressure on the Microstructure and Mechanical Properties of 2219 Al Plasma-Assisted Cold Spray Coatings

  • 期刊论文

  • 发表日期：

    2025年11月19日

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  • Chaoqun Lin,
  • Chunzhi Gong,
  • Jiaying Liu,
  • Zishuo Hao,
  • Taoding Liang,
  • Qiming Liu,
  • Yuan Liu,
  • Xiubo Tian

摘要

This study systematically investigated the effects of plasma-assisted cold spraying process and gas pressure (3.5-5.0 MPa) on the microstructure and properties of 2219 aluminum coatings. The results showed that increasing the gas pressure and introducing a plasma heat source significantly enhanced the coating thickness and improved particle bonding strength. This mechanism is attributed to the synergistic effect of gas pressure-enhanced particle kinetic energy and plasma heat source-induced particle thermal softening. The high temperature (450 °C) induced by the plasma heat source causes the decomposition of the Al2Cu phase, forming a Cu-depleted zone, as confirmed by the reduced intensity of the Al2Cu diffraction peak in XRD analysis. EBSD revealed an increase in dynamic recrystallization rate in the PACS coating, with the average grain size decreasing to 2.391 μm. In terms of mechanical properties, the bonding strength of the PACS coating increased to 43.32 at 5.0 MPa pressure, and the fracture surface exhibited ductile indentation characteristics, confirming that the plasma heat source promoted local metallurgical bonding. Additionally, the coating hardness increased to 107.98 HV (reaching 80% of the substrate hardness), and the wear rate decreased to 0.59 × 10−3 mm3/(N m), representing an 80% reduction compared to the CS coating under 3.5 MPa air pressure. This process overcomes the limitations of traditional cold spraying interface bonding by adjusting gas pressure and introducing a plasma heat source to induce thermal activation and dynamic recrystallization.