Fatigue performance of high-strength low-alloy DED-Arc components with Zn+Al2O3 low-pressure cold spray coating

Fatigue performance of high-strength low-alloy DED-Arc components with Zn+Al2O3 low-pressure cold spray coating | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Fatigue performance of high-strength low-alloy DED-Arc components with Zn+Al2O3 low-pressure cold spray coating Marc Müggenburg, Martín Altobelli, Stefan Vogts, Hendrik Jahns, and 7 more This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-7464109/v1 This work is licensed under a CC BY 4.0 License Status: Under Review Version 1 posted 5 You are reading this latest preprint version Abstract Additive manufacturing using the Directed Energy Deposition-Arc (DED-Arc) process enables the production of customized structural components from high-strength low-alloy (HSLA) steels. The layer-wise deposition results in surface waviness which affects the as-built components fatigue resistance. Additionally, the HSLA steel requires reliable corrosion protection for use in structural applications. This study investigates the applicability of Low-Pressure Cold Spray (LPCS) Zn + Al 2 O 3 coatings on as-built HSLA DED-Arc components with regard to fatigue performance and corrosion resistance. Multiple thin-walled components were manufactured using two different DED-Arc parameter sets, resulting in varying surface topographies. Selected components were coated with LPCS Zn + Al 2 O 3 and a subset of those was subjected to cyclic corrosion testing (CCT). From the thin-walled components, several sets of fatigue specimens were extracted in deposition direction and geometrically characterized using 3D scanning, before and after CCT. Surface height parameters and volumetric geometry were analyzed, followed by uniaxial fatigue testing (stress ratio R = 0.1), together with four-camera Digital Image Correlation (DIC) measurements of displacements at selected load cycles. The LPCS process enabled successful coating deposition with average Zn + Al 2 O 3 thicknesses of approx. 500 µm and the CCT confirmed its effective cathodic corrosion protection for the DED-Arc HSLA material. Differences in surface topography and fatigue strength were observed depending on the applied DED-Arc process parameters, resulting in fatigue strengths ranging from FAT 80 to FAT 125. While LPCS Zn + Al 2 O 3 coating slightly increased surface height parameters, it did not affect fatigue strength compared to uncoated as-built components. Both the as-coated and corrosion-exposed conditions exhibited fatigue strength of FAT 125. DED-Arc WAAM High-strength low-alloy steel Fatigue Digital Image Correlation Cold Spray Cyclic corrosion testing Full Text Cite Share Download PDF Status: Under Review Version 1 posted Reviewers agreed at journal 02 Sep, 2025 Reviewers invited by journal 02 Sep, 2025 Editor invited by journal 29 Aug, 2025 Editor assigned by journal 29 Aug, 2025 First submitted to journal 27 Aug, 2025 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-7464109","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":509071082,"identity":"d4f2f86d-bd3e-4c7e-98a6-a2ec21ddcdd8","order_by":0,"name":"Marc 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The layer-wise deposition results in surface waviness which affects the as-built components fatigue resistance. Additionally, the HSLA steel requires reliable corrosion protection for use in structural applications. This study investigates the applicability of Low-Pressure Cold Spray (LPCS) Zn\u0026thinsp;+\u0026thinsp;Al\u003csub\u003e2\u003c/sub\u003eO\u003csub\u003e3\u003c/sub\u003e coatings on as-built HSLA DED-Arc components with regard to fatigue performance and corrosion resistance. Multiple thin-walled components were manufactured using two different DED-Arc parameter sets, resulting in varying surface topographies. Selected components were coated with LPCS Zn\u0026thinsp;+\u0026thinsp;Al\u003csub\u003e2\u003c/sub\u003eO\u003csub\u003e3\u003c/sub\u003e and a subset of those was subjected to cyclic corrosion testing (CCT). From the thin-walled components, several sets of fatigue specimens were extracted in deposition direction and geometrically characterized using 3D scanning, before and after CCT. Surface height parameters and volumetric geometry were analyzed, followed by uniaxial fatigue testing (stress ratio \u003cem\u003eR\u003c/em\u003e\u0026thinsp;=\u0026thinsp;0.1), together with four-camera Digital Image Correlation (DIC) measurements of displacements at selected load cycles. The LPCS process enabled successful coating deposition with average Zn\u0026thinsp;+\u0026thinsp;Al\u003csub\u003e2\u003c/sub\u003eO\u003csub\u003e3\u003c/sub\u003e thicknesses of approx. 500 \u0026micro;m and the CCT confirmed its effective cathodic corrosion protection for the DED-Arc HSLA material. Differences in surface topography and fatigue strength were observed depending on the applied DED-Arc process parameters, resulting in fatigue strengths ranging from FAT 80 to FAT 125. 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