Effectiveness of Cold Spray Coating on Cast Iron to Prevent Oxidation

Cold spray is an emerging additive manufacturing process allowing particles to be coated onto surface of base material without melting. In this study, Diamalloy 1005 was successfully coated onto GJL-250 cast iron using a cold spray process, and extensive experiments were carried out to observe the effects of diffusion after heat treatment at 400, 750 and 850 °C for 3 h and to evaluate effectiveness of the coating in preventing oxide growth. It is found that the diffusion layer increases in thickness with increasing heat treatment temperature, and the diffusion layer thickness is 45 and 75 µm after the heat treatment at 400 and 850 °C respectively. The diffusion layer does not affect the effectiveness of the coating acting as a protective layer. This finding demonstrates the potential application of using cold spray coating as a protective layer for cast iron.