Additive friction stir deposition on cold sprayed barrier layer

Abstract

A method of manufacturing an article is described. At S102, the method comprises obtaining a first layer having a first face and a reverse second face, wherein the first layer comprises and/or is a first metal and wherein the first metal is a heat treatable first aluminium alloy. At S104, the method comprises providing a second layer on the first face of the first layer by cold spraying particles comprising a second metal thereupon, wherein the second metal is a second aluminium alloy. At S106, the method comprises depositing a third layer on the second layer by additive friction stir deposition using a third metal, wherein the third metal is a third aluminium alloy.

Claims

1. A method of manufacturing an article, the method comprising: obtaining a first layer having a first face and a reverse second face, wherein the first layer comprises and/or is a first metal and wherein the first metal is a heat treatable first aluminium alloy; providing a second layer on the first face of the first layer by cold spraying particles comprising a second metal thereupon, wherein the second metal is a second aluminium alloy; and depositing a third layer on the second barrier layer by additive friction stir deposition using a third metal, wherein the third metal is a third aluminium alloy; wherein: the second layer is a barrier layer; and the heat treatable first aluminium alloy is heat treated in a T or a W temper designation before providing the second layer thereon.

2. The method according to claim 1, wherein the heat treatable first aluminium alloy is a 2XXX, a 6XXX, a 7XXX or an 8XXX series wrought aluminium alloy.

3. The method according to claim 1, wherein the second aluminium alloy is a non-heat treatable second aluminium alloy.

4. The method according to claim 3, wherein the non-heat treatable second aluminium alloy is an AlMgSc based alloy, an AlMgZr based alloy, an AlMgScZr based alloy or an AlMgZrSc based alloy.

5. The method according to claim 1, wherein a thickness of the second layer is determined, at least in part, by a heat input during depositing of the third layer.

6. The method according to claim 5, wherein a ratio of respective thicknesses of the second layer to the third layer is in a range from 1:2 to 2:1.

7. The method according to claim 5, wherein the thickness of the second layer is in a range from 1 mm to 20 mm.

8. The method according to claim 1, wherein the cold spraying comprises cold spraying using helium.

9. The method according to claim 1, wherein the third aluminium alloy is a non-heat treatable third aluminium alloy.

10. The method according to claim 9, wherein the third aluminium alloy is an AlMgSc based alloy, an AlMgZr based alloy, an AlMgScZr based alloy or an AlMgZrSc based alloy.

11. The method according to claim 1, comprising aging before and/or after providing the second layer and/or the third layer.

12. The method according to claim 1, wherein a ratio of respective hardnesses of the first layer before and after depositing the third layer is in a range from 1:0.75 to 1:1.25.

13. An article comprising a cold sprayed layer AlMg(Sc, Zr) based alloy applied on a heat treatable aluminium alloy as a barrier layer, wherein the barrier layer is between the heat treatable aluminium alloy and an additive friction stir deposition aluminium alloy.

Description

BRIEF DESCRIPTION OF THE FIGURES

(1) Embodiments of the invention will now be described by way of example only with reference to the figures, in which:

(2) FIG. 1 shows a method according to an exemplary embodiment;

(3) FIG. 2 shows a method according to an exemplary embodiment, in more detail;

(4) FIG. 3 shows the method of FIG. 2, in more detail;

(5) FIG. 4 shows the method of FIG. 2, in more detail; and

(6) FIG. 5 shows an article according to an exemplary embodiment.

DETAILED DESCRIPTION OF THE FIGURES

(7) FIG. 1 shows a method 100 according to an exemplary embodiment.

(8) The method is a method of manufacturing an article.

(9) At S102, the method comprises obtaining a first layer having a first face and a reverse second face, wherein the first layer comprises and/or is a first metal and wherein the first metal is a heat treatable first aluminium alloy.

(10) At S104, the method comprises providing a second layer on the first face of the first layer by cold spraying particles comprising a second metal thereupon, wherein the second metal is a second aluminium alloy.

(11) At S106, the method comprises depositing a third layer on the second layer by additive friction stir deposition using a third metal, wherein the third metal is a third aluminium alloy.

(12) The method may include any of the steps described with respect to the first aspect.

(13) FIG. 2 shows a method according to an exemplary embodiment, in more detail. The method is a method of manufacturing an article. The method comprises obtaining a first layer 10 having a first face 11 and a reverse second face 12, wherein the first layer 10 comprises and/or is a first metal and wherein the first metal is a heat treatable first aluminium alloy.

(14) FIG. 3 shows the method of FIG. 2, in more detail. The method comprises providing a second layer 20 on the first face 11 of the first layer 10 by cold spraying particles 23 comprising a second metal thereupon, wherein the second metal is a second aluminium alloy.

(15) FIG. 4 shows the method of FIG. 2, in more detail. The method comprises depositing a third layer 30 on the second layer 20 by additive friction stir deposition 34 using a third metal, wherein the third metal is a third aluminium alloy.

(16) FIG. 5 shows an article 5 according to a comparative example.

(17) In more detail, FIG. 5 shows a photograph of a Rockwell B hardness survey of an AlMgSc alloy (i.e. a third layer) deposited (i.e. directly) on a 7050 substrate (i.e. a first layer) by additive friction stir deposition. There is no scale shown and the interface position has to be inferred but the HAZ depth appears to be around 10 mm.

(18) The solution identified is to deposit an interlayer (i.e. a second layer between the first layer and the third layer) of Scalmalloy by Cold Spraying direct from the powder condition. This interlayer forms a thermal barrier between the (hot) MELD process and the 7xxx substrate (at Room Temperature). The interlayer thickness is between 5 and 10 mm.