Improvement of Tool Steel Powder Cold Sprayability Via Softening and Agglomeration Heat Treatments

Cold spray can produce deposits from a broad range of materials but reports on cold spray of steels are still limited to the few steel families demonstrating high ductility and medium strength. Softening and agglomeration of steel powders via heat treatment in a rotary tube furnace were investigated as promising ways to improve H13 tool steel powder cold sprayability. By adjusting starting powder size, as well as heat treatment conditions (maximum temperature, cooling rate and heat treatment atmosphere), cold spray of H13 powder improved from virtually no deposition to the production of dense, sound and thick deposits with a powder deposition efficiency of 70%. Powder agglomeration, surface state, microstructure evolution and softening are identified as key factors determining the powder deposition efficiency and resulting deposit microstructure. The developed powder modification method has the potential to facilitate the cold spray of all steels subjected to martensitic transformation.