Effect of Pulsed Laser Ablation and Continuous Laser Heating on the Adhesion and Cohesion of Cold Sprayed Ti-6Al-4V Coatings

The individual and cumulative effects of in situ pulsed laser ablation and continuous laser pre-heating on adhesion and cohesion strength of cold sprayed Ti-6Al-4V coatings are investigated. Laser beams were coupled to a cold spray gun in order to ablate and pre-heat the substrate surface a few milliseconds prior to the impact of the spray particles. Cohesion and adhesion strength were evaluated by scratch test, standard ASTM C633 pull test and laser shock (LASAT) technique. The effects of laser ablation before and during cold spray operations were investigated. Results demonstrate that laser ablation of the substrate before cold spraying led to a smooth surface which improved adhesion strength. However, when laser ablation was maintained throughout the cold spray process, i.e., in between the coating layers, a reduction of cohesion and adhesion was observed. These negative effects were circumvented when laser ablation and laser pre-heating were combined.