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Ta coatings were cold sprayed onto carbon steel and exposed to two different solutions: (i) synthetic seawater and (ii) aqueous 15% HCl to test the suitability to mitigate the corrosion of the substrate.
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Cold Spray (CS) is a solid-state deposition repair method that deposits 1-50um powder particles onto a substrate. A compressed gas acts as carrier to accelerate the particles through a converging-diverging nozzle to the substrate at supersonic speeds. Critical impact velocity is the velocity that is required to achieve sufficient bonding. CS process parameters as well as powder properties can be adjusted to achieve such velocities. The type of carrier gas will also change the spray velocity. Helium has the lowest molecular weight which allows for higher gas and particle velocity upon impact.
Supersonic particle deposition also known as cold dynamic gas spray, or “Cold Spray” is a materials deposition process. During the cold spray process a gas stream, typically helium or nitrogen, is split into two streams where 90% of the gas is sent to an electric heater and 10% is sent to a powder feeder. The powder feeder contains powder composed of small metallic particles, or blends of metallic and non-metallic particles, ranging from 5 to 100 μm in size.
The need for corrosion mitigation and repair is a perennial concern for a wide array of industries. An attractive evolution in coatings application for mitigating the effects of environmental/operational degradation is cold spray of metallic replacement layers. As cold spray technologies continue to become more commonplace, portable, low-pressure cold spray systems presents an opportunity to bring metallic repair to the field for heavily damaged or corroded assets.