Laser Heat Treatment of Ti Coatings
Laser Heat Treatment of Ti Coatings
Laser Heat Treatment of Ti Coatings
Presented to
Dr. Dineshkumar Harursampath (Associate Professor, A.E Deptt. , Indian Institute of Science)
Dr. Ramesh Gupta (Associate Professor, M.E Deptt. , Shiv Nadar University)
Prepared By
Mrinal Manoj
Contents
1. Abstract
2. Advantages of using Cold Spray Deposition technique
To study the optimal parameters for the laser heat treatment of cold sprayed Titanium Grade II coating on an Aluminium 2024-T3
substrate in order to enhance the mechanical properties of the coating, in terms of bond strength, hardness, and tensile strength to
prevent corrosion and wear of the substrate
Cold Spray Deposition technique
• In this process, high-temperature compressed gases (typically nitrogen, air, or helium) are used as the propulsive gas to accelerate powder
feedstock (typically metals and metal matrix composites) to a high velocity (typically higher than 300 m/s), and to induce deposition when
the powders impact onto a substrate (typically metals).
• Experimental conditions for the cold spray deposition in the given research paper is as follows:
Parameter Value
*Helium is used as the propulsive gas in order to prevent the Titanium from oxidizing during the cold spray deposition process.
• There are two types of Cold spray deposition techniques:
High Pressure Cold Spray (H.P.C.S) system Low Pressure Cold Spray (L.P.C.S) system
Propulsive gas pressure is greater than 1 MPa. Propulsive gas pressure is less than 1 MPa.
The gas stream is split into 2 streams, one stream is called the In Low pressure cold spray system, the air is first compressed, then
carrier gas which contains the metallic powder that is to be sprayed heated and then is made to carry the powdered metal. There is no
and the other stream heats up the compressed gas. splitting of streams.
High pressure compressed gas (propulsive gas) is used. A normal air compressor is used.
Porosity of the sprayed coating is less than 1%. Porosity of the sprayed coating ranges from 2% to 11%.
Its expensive and not very flexible in terms of equipment and Its cheaper and more flexible in terms of equipment and processing
processing costs. costs.
Fig.1. High Pressure Cold Spray (H.P.C.S) system Fig.2. Low Pressure Cold Spray (L.P.C.S) system
Advantages of using Cold Spray Deposition technique
Its suitable to deposit titanium on aluminum alloy substrates by avoiding overcoming the aging temperature than other thermal spray
deposition technologies.
It has high deposition efficiency. Deposition efficiency is defined as the ratio of the weight of adhered particles (particles attached to the
substrate) to the total weight of sprayed particles.
1 Zahiri et al Investigated the effect Observed a reduction in the number of macro-pores within the deposit due to
of annealing post the formation of metallurgical bonds between the particles and the
treatment on the cold elimination of the particle–particle interface and reported an improvement in
sprayed titanium. the ductility due to the grain growth. On the other hand, the annealing
resulted in a reduction of the tensile strength of approximately 25%
compared to the as-sprayed titanium and the formation of micro-pores.
2 Hussain et al Investigated the effect Observed that the heat treatment was able to reduce the volume percentage of
of post deposition macro- and micro-pores by approximately 80% and 60%, respectively.
vacuum heat treatment However, these treatments involve the heating of the whole coating-substrate
on the cold sprayed system, and usually employ relatively high temperatures that are not suitable
titanium. in the case of aluminium alloy substrates.
3 Marrocco et al Investigated the effect Observed that it eliminates the residual micro-porosity and forms a high-
of post deposition laser quality corrosion barrier layer without any deleterious effect on the substrate.
heat treatment on the
cold sprayed titanium.
Numerical model and theory description
Analysis Type
Computational Domain
Coating-substrate systems
● CASE A: Consists of only the cold sprayed titanium coating of 2mm thickness.
● CASE B: Consists of the cold sprayed titanium coating and the aluminium substrate, both having thickness of 2mm.
● CASE C: Consists of the cold sprayed titanium coating of thickness 0.4mm and aluminium substrate of thickness 2mm.
Parameter Value
Scan length, L 60 mm
All properties of the titanium coating were assumed temperature dependent, conversely physical and thermal
properties for the aluminium substrate were set as constant.
Thermo-physical properties
Thermo-physical properties
Property Temperature
Specific heat capacity (J·kg−1·K−1) 540 540 540 540 540 540 540
Thermal conductivity (W·m−1·K−1) 16.3 16.3 16.3 16.3 16.3 16.3 16.3
Coefficient of thermal expansion ×10−6 (K−1) 8.60 8.76 8.97 9.29 9.50 9.70 9.86
Mechanical Properties
Equations used
Where, The Gaussian heat flux distribution equation for Laser beam
Where,
Where,
Where,
Where,
● α = Thermal expansion coefficient (K−1)
● ∆T = Temperature gradient ● E = Young’s modulus
● ν = Poisson’s ratio
Where,
● σ = Stress
● D = Stiffness matrix
Procedure for Transient Thermal Analysis
1. A transient thermal coupled with a transient structural ANSYS schematic was made.
3. In the Geometry tab, a model of the computational domain was made in Solidworks and exported to ANSYS Design modeler.
4. In the Model tab, the following conditions were set:
a) The materials were assigned to the respective segments of the computational domain.
b) The meshing was generated with element size of 0.5 mm and number of elements as 48000.
Fig.9. Structural meshed model of the coating-substrate system for the thermo-mechanical analysis
c) For the Transient thermal analysis conditions:
i. Initial temperature = 20 °C
ii. For the Analysis settings, number of steps was set to be 140 and Auto Time stepping was kept on Program Controlled
iii. A convective heat transfer coefficient ( Film Coefficient) of 10 W/m 2.°C was given to all faces of the geometry.
iv. The moving Gaussian heat flux distribution was achieved by using an ANSYS add-on (installation link provided in
Appendix), the Laser Power Intensity was given as 6769942.42 W/m 2 and the Radius of the beam as 0.0015 m, for more
details regarding the setup of the Laser heat source refer the report in Point 2 in the Appendix.
Fig.12. Geometry, Path and Start Point for the Moving Heat Flux (Laser Beam)
6. All the data retrieved from the temperature probe was converted into an Excel document and the various graphs were plotted.
Fig.13. Top view of Temperature analysis of CASE B at 12.5 mm/min scan speed at 72.5 secs.
Fig.14. Isometric cross sectional view of Temperature analysis of CASE B at 12.5 mm/min scan speed at 72.5 secs.
Results of Transient Thermal Analysis
Fig.15. Right side cross sectional of Temperature analysis of CASE B at 12.5 mm/min scan speed at 72.5 secs. The cross section is perpendicular to the laser scan direction.
Fig.16. Right side cross sectional close-up view of Temperature analysis of CASE B at 12.5 mm/min scan speed at 72.5 secs. The cross section is perpendicular to the laser scan direction.
Fig.17. Top view of Total Heat Flux of CASE B at 12.5 mm/min scan speed at 72.5 secs
Fig.18. Isometric cross sectional view of Total Heat Flux of CASE B at 12.5 mm/min scan speed at 72.5 secs.
Fig.19. Right side cross sectional view of Total Heat Flux of CASE B at 12.5 mm/min scan speed at 72.5 secs. The cross section is perpendicular to the laser scan direction.
Fig.20. Right side cross sectional close-up view of Total Heat Flux of CASE B at 12.5 mm/min scan speed at 72.5 secs. The cross section is perpendicular to the laser scan direction.
Graph 1. Computed transient thermal profiles for all cases at all Laser scan speeds
Graph 2. Computed transient thermal profiles for all cases at Laser scan speed of 200 mm/min
Graph 3. Computed transient thermal profiles for all cases at Laser scan speed of 1000 mm/min
● The main challenge of the proposed laser treatment is to promote the formation of rutile titanium dioxide on the surface of the coating with
improved mechanical properties and good adhesion with the underlying cold-sprayed titanium. To accomplish this, a temperature of
approximately 500 °C should be reached on the titanium surface.
● From Graph 1, we can see that all the cases having laser scan speed of 1000 mm/min do not satisfy the above criteria. We can infer from
this result that the formation of a compact layer of titanium dioxide depends on the scan speed of laser beam. Increasing the laser speed
resulted in a decrease in the maximum predicted temperature.
● There were two distinct cases of coating damage that were observed:
○ For the cases where the rutile layer was formed, “Material loss” on the treated surface, resulting in clear macro-porosities and
craters on the irradiated surface was observed.
○ For the cases having laser scan speed of 1000 mm/min, crack evidence was found along the surface and through the thickness of the
coating, suggesting the excessive tendency to catastrophic failure.
● The graph also points out that the aluminium substrate acts like a heat sink drawing the heat from the titanium coating due to the higher
thermal conductivity of aluminium influencing the maximum temperatures achieved on the coating surface.
● The substrate layer also affects the heating and cooling rates of the irradiated surface. Taking the scan speed of 12.5 mm/min for all the
cases as an example, we can see that temperature profiles for CASE B and CASE C have much narrower shape than CASE A suggesting
the occurrence of more severe transient conditions. Due to these fast heating and cooling rates, a large thermal gradient occurs at that time
influencing the development of residual stresses within the coating.
● The Thickness Ratio of the test subject also played a vital role in the heating and cooling of the coating.
Procedure for Transient Structural Analysis
4. A stress probe and strain probe were placed at the same distance as the transient thermal analysis. The probes are used to measure the stress
and strain perpendicular to the laser scan direction, in this case it’s the X-axis.
Results of Transient Structural Analysis
● The heated material expands, but the surrounding material restrains the movement of the heated part exerting on it a compressive action.
● During the cooling phase, a tensile stress state occurs in the irradiated region, while the material underneath this zone is subjected to a
compressive stress field
Fig.25. Formation of thermal stress and strain induced by the temperature gradient from the laser beam.
Fig.26. Cross section of Stress analysis of CASE A at 12.5 mm/min scan speed in the X direction at 13 secs.
Fig.27. Cross section of Stress analysis of CASE A at 12.5 mm/min scan speed in the X direction at 72.5 secs.
Fig.28. Cross section of Stress analysis of CASE A at 12.5 mm/min scan speed in the X direction at 144 secs.
● From Fig.26, as the object is in room temperature, it was observed that a tensile force (+ve stress value) acts at the region of interest.
● When the laser beam moves to the point of interest i.e., at 72.5 secs, due to the heating of the titanium, it expands and due to this
expansion, a compressive stress (-ve stress value) is exerted by the surrounding material to resist the expansion of the heated material.
Hence the blue colour suggesting a compressive stress being generated as shown in the Fig.27.
● As the laser beam moves away from the point of interest, due to the cooling of the titanium, it contracts and due to this contraction, a
tensile stress is exerted by the surrounding material to resist the contraction of the heated material. Hence the red colour suggesting a
tensile stress being generated as shown in the Fig.28.
Graph 4. Transient thermal stress and strain profiles in test Case A at laser scan speed of 12.5 mm/min : distribution of the stresses within the cross section perpendicular to the laser
scan direction i.e. the X- axis in this case.
● From Graph 4, we can observe that, at the beginning of the treatment, the observed element experienced tensile stresses that reached a
maximum value of 20 MPa at 13 secs.
● When the laser beam reaches at the point of interest i.e., 72.5 secs, the maximum compressive stress experiences by the material is
approximately equal to 50 MPa.
● At the end of the process after cooling, the material results to be subjected to a low residual tensile load below 10 MPa.
Graph 5. Distributions of stresses along the perpendicular (X) and parallel (Y) directions to laser scan direction with the laser track distance for the different test cases at the end of the
process.
● From Graph 5, it is observed that a slight variation of the residual stresses inside the track can be observed in all cases moving from the
beginning to the end of the track.
● The stress in the test Case A_12.5 showed a uniform distribution of the stresses both in the X and Y directions, with changes in the stress
field only in the irradiated region at the end of the track. The absence of the substrate coupled with the slower laser reduced the heat
dissipation from the irradiated surface through the underlying deposited titanium to the surrounding ambient at room temperature. From
Graph 1, CASE A at 12.5 mm/min experienced a less sharp thermal gradient allowing to attenuate the stress state within the material.
● The other two test Cases (i.e., A_200 and B_200) showed a more pronounced variation of the X stress along the laser path.
● Due to the higher laser speed in CASE A_200 and CASE B_200, larger temperature gradients were formed and there was a noticeable
variation in stress. This phenomenon is more profound in the test Case B_200 where a more effective heat dissipation took place due to the
presence of the aluminum substrate.
Fig.29. Von Mises stress for the different process configurations along with micrographies of the treated coatings cross sections
● By observing the equivalent Von Mises stresses in Fig.29,we can see the overall stress state inside the material, and it can be used to
understand the crack formation in the various substrate coating systems.
● The surface in CASE A_12.5 and CASE B_200, experienced values between 10 and 20 MPa, far below the elastic limit of the materials.
Therefore, no crack formation is expected.
● For all scenarios of CASE A, material losses are observed as depicted in Fig.29 (d)
● For CASE B_12.5, the stresses in both X and Y directions on the surface of the coating are mainly compressive and attained values are in
the range between -60 to -40 MPa which is higher than the latter of the two cases. This case has the best coating formation as depicted in
Fig.29 (c).
● For CASE C_12.5, the equivalent Von Mises stresses exceeds the safe limit and hence cracks are formed as shown in Fig.29 (b).
Conclusions
● Highest predicted temperatures have been observed on the surface of samples processed at lower laser scan speed. The presence of a
substrate influences the maximum temperature achieved on the surface as well as the cooling rate experienced by the material.
● Higher scan speed attains reduced value of temperature and material experiences sharper thermal gradients during the heating and cooling.
The substrate showed to have a reduced influence on the temperature levels in comparison with the samples treated at lower speed.
● Compressive stresses have been found on the test case with thickness ratio equal to 1, processed with a laser scan speed of 12.5 mm/min
(Case B at 12.5 mm/min). Compressive stress field inside the material are beneficial for reducing the failure tendency and enhancing the
fatigue endurance of the deposit.
● A tensile stress field was observed in the sample with thickness ratio <1, adopting 12.5 mm/min as laser scan speed (Case C at 12.5
mm/min). High value of the equivalent Von Mises stress was predicted inside the coating due to the sharp thermal gradient and the reduced
thickness of the titanium deposit. The stress overcame the tensile strength of the cold-sprayed titanium pointing out the high risk of
nucleation and propagation of cracks inside the coating.
● Reduced tensile stresses were found in the other test cases analysed. The predicted stress field was too low to cause the formation of cracks
inside the material. The mechanical model was not able to explain the occurrence of the observed material loss. This kind of damage can be
related to the weakness of the rutile layer produced and the mismatching with the underlying ductile metal.
● The proper matching between the laser heat input and the thickness ratio between the titanium coating and the aluminium substrate play a
key role in the laser treatment. Indeed, the ability of the substrate to dissipate the heating from the coating allowed it to obtain the proper
temperature distribution inside the coating, avoiding the overheating of the surface or ineffective treatment.
● In case of ratio between the coating and substrate thickness approximately equal to 1, a higher heat input can be adopted to promote the
formation of a compact and dense titanium oxide layer. High laser energy input should be avoided in the case of reduced value of the
thickness ratio.
References
1. Bae, G.; Kumar, S.; Yoon, S.; Kang, K.; Na, H.; Kim, H.-J.; Lee, C. Bonding features and associated mechanisms in kinetic sprayed
titanium coatings. Acta Mater. 2009, 57, 5654–5666.
2. Boyer, R.R. An overview on the use of titanium in the aerospace industry. Mater. Sci. Eng. A 1996, 213,103–114.
3. Astarita, A.; Rubino, F.; Carlone, P.; Ruggiero, A.; Leone, C.; Genna, S.; Merola, M.; Squillace, A. On the improvement of AA2024 wear
properties through the deposition of a cold-sprayed titanium coating. Metals 2016, 6, 185.
4. Rubino, F.; Astarita, A.; Carlone, P.; Genna, S.; Leone, C.; Memola Capece Minutolo, F.; Squillace, A. Selective laser post-treatment on
titanium cold spray coatings. Mater. Manuf. Process. 2016, 31, 1500–1506.
5. Carlone, P.; Astarita, A.; Rubino, F.; Pasquino, N.; Aprea, P. Selective laser treatment on cold-sprayed titanium coatings: Numerical
modeling and experimental analysis. Metall. Mater. Trans. B 2016, 47, 3310–3317.
6. ASM Specialty Handbook: Aluminum and Aluminum Alloys; Davis, J.R. (Ed.) ASM International: Materials Park, OH, USA, 1993; ISBN
978-0-87170-496-2.
7. Duncan, R.M.; Hanson, B.H.; Design Council; British Standards Institution; Council of Engineering Institutions. The Selection and Use of
Titanium; Oxford University Press for the Design Council, the British Standards Institution, the Council of Engineering Institutions:
Oxford, UK, 1980; ISBN 0198591764.
8. Luzin, V.; Spencer, K.; Zhang, M.; Matthews, N.; Davis, J.; Saleh, M. Residual stresses in cold spray coatings. In Cold-Spray Coatings;
Cavaliere, P., Ed.; Springer International Publishing: Cham, Switzerland, 2018; pp. 451–480.
9. Larsson, P.-L.; Giannakopoulos, A.E. Tensile stresses and their implication to cracking at pyramid indentation of pressure-sensitive hard
metals and ceramics. Mater. Sci. Eng. A 1998, 254, 268–281.
10. Marrocco, T.; McCartney, D.G.; Shipway, P.H.; Sturgeon, A.J. Production of titanium deposits by cold-gas dynamic spray: Numerical
modeling and experimental characterization. J. Therm. Spray Technol. 2006, 15, 263–272.
Appendix
1. Installation link of the ANSYS moving heat source add-on along with documentation.
https://catalog.ansys.com/product/5b3bc6857a2f9a5c90d32e7e/moving-heat-source?creator=ANSYS%20Inc
https://drive.google.com/file/d/16HX-_yWDozXdI50LVuYCvJ6ebtSSexfz/view?usp=sharing
3. APDL SCRIPT.
The APDL script for Laser scan speed of 12.5 mm/min is given below:
*DEL,_FNCNAME
*DEL,_FNCMTID
*DEL,_FNCCSYS
*SET,_FNCNAME,'HEAT_FLX'
*SET,_FNCCSYS,0
! /INPUT,.\Desktop\Ti coating analysis\ANALYSIS\Substrate + 2mm coating\APDL INPU FILES\12.5mmmin.func,,,1
*DIM,%_FNCNAME%,TABLE,6,24,1,,,,%_FNCCSYS%
!
! Begin of equation: 6769942.42*exp(-2*(({X}-0.05)^2+({Y} !0.0002*{TIME})^2)/0.0015^2)
*SET,%_FNCNAME%(0,0,1), 0.0, -999
*SET,%_FNCNAME%(2,0,1), 0.0
*SET,%_FNCNAME%(3,0,1), 0.0
*SET,%_FNCNAME%(4,0,1), 0.0
*SET,%_FNCNAME%(5,0,1), 0.0
*SET,%_FNCNAME%(6,0,1), 0.0
*SET,%_FNCNAME%(0,1,1), 1.0, -1, 0, 0, 0, 0, 0
*SET,%_FNCNAME%(0,2,1), 0.0, -2, 0, 1, 0, 0, -1
*SET,%_FNCNAME%(0,3,1), 1, -3, 0, 1, -1, 2, -2
*SET,%_FNCNAME%(0,4,1), 0.0, -1, 0, 2, 0, 0, -3
*SET,%_FNCNAME%(0,5,1), 0.0, -2, 0, 1, -3, 3, -1
*SET,%_FNCNAME%(0,6,1), 0.0, -1, 0, 0.05, 0, 0, 2
*SET,%_FNCNAME%(0,7,1), 0.0, -3, 0, 1, 2, 2, -1
*SET,%_FNCNAME%(0,8,1), 0.0, -1, 0, 2, 0, 0, -3
*SET,%_FNCNAME%(0,9,1), 0.0, -4, 0, 1, -3, 17, -1
*SET,%_FNCNAME%(0,10,1), 0.0, -1, 0, 0.0002, 0, 0, 1
*SET,%_FNCNAME%(0,11,1), 0.0, -3, 0, 1, -1, 3, 1
*SET,%_FNCNAME%(0,12,1), 0.0, -1, 0, 1, 3, 2, -3
*SET,%_FNCNAME%(0,13,1), 0.0, -3, 0, 2, 0, 0, -1
*SET,%_FNCNAME%(0,14,1), 0.0, -5, 0, 1, -1, 17, -3
*SET,%_FNCNAME%(0,15,1), 0.0, -1, 0, 1, -4, 1, -5
*SET,%_FNCNAME%(0,16,1), 0.0, -3, 0, 1, -2, 3, -1
*SET,%_FNCNAME%(0,17,1), 0.0, -1, 0, 0.0015, 0, 0, 0
*SET,%_FNCNAME%(0,18,1), 0.0, -2, 0, 2, 0, 0, -1
*SET,%_FNCNAME%(0,19,1), 0.0, -4, 0, 1, -1, 17, -2
*SET,%_FNCNAME%(0,20,1), 0.0, -1, 0, 1, -3, 4, -4
*SET,%_FNCNAME%(0,21,1), 0.0, -1, 7, 1, -1, 0, 0
*SET,%_FNCNAME%(0,22,1), 0.0, -2, 0, 6769942.42, 0, 0, -1
*SET,%_FNCNAME%(0,23,1), 0.0, -3, 0, 1, -2, 3, -1
*SET,%_FNCNAME%(0,24,1), 0.0, 99, 0, 1, -3, 0, 0
! End of equation: 6769942.42*exp(-2*(({X}-0.05)^2+({Y} !0.0002*{TIME})^2)/0.0015^2)
!-->
sf,Surface,HFLUX, %HEAT_FLX%
THANK YOU