Effects of Thermal Spray Coatings on Surface Protection and Mechanical Performance of AlSi10Mg Alloy Produced by Additive Manufacturing

Year 2025, Volume: 11 Issue: 2, 206 - 213, 31.08.2025

Abdülcelil Bayar , Gözde Altuntaş

Abstract

In this study, AlSi10Mg alloy produced by additive manufacturing was produced as a tensile test sample according to ASTM E-8 standard. The produced materials were subjected to coating process with 60% Al2O3-40% TiO2 and 87% Al2O3-13% TiO2 powder mixtures at two different rates with powder flame spray coating, which is one of the thermal spray coating methods. After coating, tensile test of the samples was performed and the most suitable mixing ratio of Al2O3 and TiO2 mixtures was determined and the strength ratios were compared. In addition to these, the post-corrosion strength values of the samples subjected to salt spray test after coating were examined and the effects of both different coating rates and corrosion were investigated. The changes on the surface after corrosion process and the fracture surface examinations of the samples after tensile test were examined with scanning electron microscope (SEM). The results showed that the sample coated with 60% Al2O3-40% TiO2 without corrosion process had the highest strength value with a value of 437.65 Mpa. It was observed that the samples coated with 87% Al2O3-13% TiO2 caused a decrease in the strength value compared to the untreated uncoated sample

Keywords

Additive manufacturing , corrosion , AlSi10Mg , thermal spray coating

Thanks

This work was supported by TUSAŞ. The authors are grateful to TUSAŞ for providing laboratory facilities.

References

• [1] I. Gibson, D.W. Rosen and B. Stucker, “Design for additive manufacturing,” Additive Manufacturing Technologies, pp. 10–18, Springer, Boston, MA (2010). doi: 10.1007/978-3-030-56127-7_19
• [2] K. Kempen, L. Thijs, J. Van Humbeeck and J. P. Kruth, “Mechanical properties of AlSi10Mg produced by selective laser melting,” Physics Procedia, vol. 39, pp. 439-446, 2012. doi: 10.1016/j.phpro.2012.10.059 [3] P. Vasanthakumar, K. Sekar and K. Venkatesh, “Recent developments in powder metallurgy based aluminium alloy composite for aerospace applications,” Materials Today: Proceedings, vol. 18, pp. 5400-5409, 2019. doi: 10.1016/j.matpr.2019.07.568
• [4] D. Ding, Z. Pan, D. Cuiuri and H. Li. “Wire-feed additive manufacturing of metal components: technologies, developments and future interests,” The International Journal of Advanced Manufacturing Technology vol. 81, pp. 465-481, 2015. doi: 10.1007/s00170-015-7077-3
• [5] W. Shifeng, L. Shuai, W. Qingsong, C. Yan, Z. Sheng and S. Yusheng, “Effect of molten pool boundaries on the mechanical properties of selective laser melting parts,” The International Journal of Advanced Manufacturing Technology, vol. 214, no. 11, pp. 2660-2667, 2014. doi: 10.1016/j.jmatprotec.2014.06.002
• [6] P. Ganesh, R. Giri, R. Kaul, P.R. Sankar, P. Tiwari, A. Atulkar and L.M. Kukreja, “Studies on pitting corrosion and sensitization in laser rapid manufactured specimens of type 316L stainless steel,” Materials & Design, vol. 39, pp. 509-521, 2012. doi: 10.1016/j.matdes.2012.03.011
• [7] N.L. Sukiman, X. Zhou, N. Birbilis, A.E. Hughes, J.M.C. Mol, S.J. Garcia and G.E. Thompson, “Durability and corrosion of aluminium and its alloys: overview, property space, techniques and developments,” Aluminium Alloys-New Trends in Fabrication and Applications, vol .5, pp. 47-97, 2012.
• [8] C. Linder, B. Mehta and S. Sainis, “Corrosion resistance of additively manufactured aluminium alloys for marine applications,” npj Mater Degradation, vol. 8, no. 46, 2024. doi: 10.1038/s41529-024-00459-5
• [9] B.D. Craig and D.S Anderson, Handbook of corrosion data, ASM international, 1994
• [10] M. Rafieazad, M. Mohammadi and A.M. Nasiri, “On microstructure and early stage corrosion performance of heat treated direct metal laser sintered AlSi10Mg,” Additive Manufacturing, vol. 28, pp. 107–119, 2019. doi: 10.1016/j.addma.2019.04.023
• [11] B. Mehta, L. Nyborg, K. Frisk and E. Hryha, “Al–Mn–Cr–Zr-based alloys tailored for powder bed fusion-laser beam process: Alloy design, printability, resulting microstructure and alloy properties,” Journal of Materials Research, vol. 37, pp. 1256–1268, 2022. doi: 10.1557/s43578-022-00533-1
• [12] J. Esquivel and R.K. Gupta, “Corrosion-resistant metastable Al alloys: an overview of corrosion mechanisms,” Journal of The Electrochemical Society, vol. 167, no. 81504, 2020. doi: 10.1149/1945-7111/ab8a97
• [13] D. Kong, C. Dong, X. Ni and X. Li, “Corrosion of metallic materials fabricated by selective laser melting,” npj Materials Degradation, vol. 3(1), no. 24, 2019. doi: 10.1038/s41529-019-0086-1
• [14] M.R. Dorfman, Thermal spray coatings, In Handbook of environmental degradation of materials, William Andrew Publishing, pp. 469-488, 2018. doi: 10.1016/B978-0-323-52472-8.00023-X
• [15] L. Pawlowski, The science and engineering of thermal spray coatings, John Wiley & Sons, 2008.
• [16] Y. Akçin, O. Asi and Ö. Yeşil, “Kompozit malzemelerin kaplanabilirliğinin incelenmesi,” Pamukkale Üniversitesi Mühendislik Bilimleri Dergisi, vol. 19, no. 7, pp. 319-322, 2013. doi: 10.5505/pajes.2013.52724
• [17] J.G. Miranda-Hernández, S. Moreno-Guerrero, A.B. Soto-Guzman and E. Rocha-Rangel, “Production and characterization of Al2O3-Cu composite materials,” Journal of Ceramic Processing Research, vol. 7, no. 4, pp. 311-314, 2006.
• [18] H. Gün and D. Asi, “Al2O3-TiO2 (% 97-3) Seramik Toz Parçacık İlaveli Cam Elyaf Takviyeli Epoksi Matrisli Kompozit Malzemelerin Mekaniksel Özelliklerinin İncelenmesi,” Uşak Üniversitesi Fen ve Doğa Bilimleri Dergisi, vol. 1, no. 1, pp. 33-40, 2017.
• [19] K.A. Habib, J.J. Saura, C. Ferrer, M.S. Damra, E. Giménez and L. Cabedo, “Comparison of flame sprayed Al2O3/TiO2 coatings: Their microstructure, mechanical properties and tribology behavior,” Surface and coatings technology, vol. 201, no. 3-4, pp. 1436-1443, 2006. doi: 10.1016/j.surfcoat.2006.02.011
• [20] W.D. Callister Jr and D.G. Rethwisch, Materials science and engineering: an introduction. John wiley & sons, 2020
• [21] P. Fauchais and A. Vardelle, Thermal sprayed coatings used against corrosion and corrosive wear, Advanced plasma spray applications, vol. 10, no. 34448, 2012.
• [22] M. Ozer, Y. Kaplan, A. Ozer and S. Aksoz, “Influence of different sintering techniques on the wear properties of Al-15Si-2.5 Cu-0.5 Mg/B4C composites,” Science of Sintering, vol. 56(3), pp. 269-283, 2024. doi: 10.2298/SOS231003060O
• [23] A.G. Evans and B.J Dalgleish, “The fracture resistance of metal-ceramic interfaces,” Acta metallurgica et materialia, vol. 40, pp. S295-S306, 1992. doi: 10.1016/0956-7151(92)90289-Q