A numerical Approach to design and develop freestanding porous structures through cold spray multi-material deposition

Impact Deposition Behavior of Al/B4C Cold-Sprayed Composite Coatings: Understanding the Role of Porosity on Particle Retention

“…Instead, the method that we used here to validate the model compromises between the element numbers (capturing the relevant physics based on the literature [ 43 , 44 , 81 ]) and computational time, which has been used in the literature to compare the different numerical methods (e.g., CEL, ALE, and Lagrangian) to show the efficiency and accuracy of the models [ 44 ]. It is worth noting that each numerical FE technique can simulate a different aspect of the cold spray deposition process [ 72 ]. The ALE technique provides high precision and is mainly used in the literature [ 70 , 73 ] to simulate the build-up process of coatings and multi-particle impacts [ 82 ]; considering its advantages, we will also use the ALE technique here for further analysis in the future.…”

“…Next, Figure 3 shows the PEEQ value over the contact-surface of the substrate and the particle simulated in this study and compared with similar models in the literature [ 44 , 45 ]. We compare this to determine if our implementation produces results of similar magnitudes and trends to those published in the literature concerning the impact deposition of ceramic particles into metal substrates [ 43 , 44 , 46 , 72 , 79 ]. In Figure 3 a, the PEEQ value over the Al contact-surface in our Al/B C coating in the current study and in Al/Al coating reprinted from the literature [ 44 ] with a particle diameter of 25 m and impact velocity of 700 m/s shows that the plastic strain of the Al substrate in this simulation is comparable to previous studies [ 44 ].…”

“…However, the SEM images in the literature [ 2 , 12 , 28 , 33 ] show larger pore sizes for larger particles and smaller pores for relatively smaller particle diameters. The results suggest that the ratio of the pore to particle size should be considered in manufacturing the porous structure using cold spraying [ 72 ].…”

“…The friction coefficient is considered to be 0.25 for the contact between particle and substrate, and this is guided by the literature [ 71 ]. The interaction between the particle and the substrate is defined using the general contact algorithm, which has been implemented previously in the literature [ 44 , 46 , 72 ]. For employing the ALE method [ 70 ], the frequency is set at ten as a default value [ 70 , 73 ], and the number of remeshing sweeps per increment is set between 5 to 8 for various models in order to avoid errors in analysis [ 74 , 75 ].…”

Thermographic Analysis of Composite Metallization through Cold Spray

“…The main applications in the literature deal with metal-to-metal coatings to enhance the performance of the coated system regarding wear, corrosion, fatigue, etc. [1,2]; CS has also been suggested for additive manufacturing of freestanding parts [3,4]. However, recently, attention is also moving towards metal-to-composites with polymers or polymeric matrix composites substrates; this last application is known as polymer metallization.…”