An Experimental and Finite Element Study of Cold Spray Copper Impact onto Two Aluminum Substrates

King, Peter C.; Bae, Gyuyeol; Zahiri, Saden H.; Jahedi, Mahnaz; Lee, Changhee

doi:10.1007/s11666-009-9454-7

Cited by 181 publications

(70 citation statements)

References 42 publications

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“…In cold spraying, particles remains its solid state in gas jet, hence their high velocity is necessary, so as to brake thin film of oxides on the substrate and to connect with pure metals. This confirm theory that some minimum critical velocity υ c exists which provides sufficient kinetic energy E k , when powder contacts substrate, to ensure its depositing [13]. Exceeding the critical velocity is directly related with attaining high productivity of the process, which translates into desirable thickness of the coating at low powder loss.…”

Section: Introductionsupporting

confidence: 78%

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Effect of Gas Pressure and Temperature on Stereometric Properties of Al+Al2O3 Composite Coatings Deposited by LPCS Method

Winnicki¹,

Piwowarczyk²,

Małachowska³

et al. 2014

Archives of Metallurgy and Materials

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The paper deals with effect of working gas pressure and temperature on surface stereometry of coatings deposited by low-pressure cold spray method. Examinations were focused on aluminium coatings which are commonly used to protect substrate against corrosion. A commercial Al spherical feedstock powder with admixture of Al 2 O 3 (Al + 60wt.-% Al 2 O 3 ), granulation -50+10 µm, was used to coat steel, grade S235JR. The deposited coatings were studied to determine their stereometry, i.e. roughness, transverse and longitudinal waviness, topography of surface and thickness as the functions of gas pressure and temperature. A profilometer and focal microscope were used to evaluate the stereometric properties. In order to reduce the number of variables, the remaining process parameters, i.e. shape and size of de Laval nozzle, nozzle-to-substrate distance, powder mass flow rate, linear velocity of spraying gun, were kept unchanged. The investigation confirmed influence of temperature and pressure on coating thickness as well as on the surface seterometry.Keywords: Cold Spray, metal-matrix composite, roughness, waviness W artykule przedstawiono wpływ ciśnienia i temperatury gazu roboczego na sterometrię powierzchni powłok nakładanych za pomocą niskociśnieniowej metody natryskiwania na zimno. Powłoki na podłożu stalowym S235JR zostały wykonane przy użyciu komercyjnie dostępnego proszku Al z dodatkiem Al 2 O 3 (20% Al/80% Al 2 O 3 wagowo) o granulacji <50 µm, zostały wykonane powłoki na podłożu stalowym S235JR. Następnie za pomocą profilometru i mikroskopu konfokalnego określono właściwości stereometryczne powłok takie jak chropowatość, falistość, topografię powierzchni oraz grubość w funkcji temperatury i ciśnienia gazu roboczego. W celu zminimalizowania ilości zmiennych pozostałe parametry procesu nie były zmieniane. Badania potwierdziły wpływ ciśnienia i temperatury gazu na stereometrię powierzchni.

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Section: Introductionsupporting

confidence: 78%

“…Additionally, as a result of compacting the ductile metal with hard phase, essentially lower porosity could be attain, from 30% for pure aluminium even down to 1% [10,15]. Also the coating adhesion to substrate is thus increased even to 40-80 MPa [13] and likewise the hardness and abrasion resistance are improved [16].…”

Section: Introductionmentioning

confidence: 99%

Effect of Gas Pressure and Temperature on Stereometric Properties of Al+Al2O3 Composite Coatings Deposited by LPCS Method

Winnicki¹,

Piwowarczyk²,

Małachowska³

et al. 2014

Archives of Metallurgy and Materials

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“…According to these studies, ASI may lead to partial melting for certain combinations of materials and impact conditions [75]. However, there is no consensus on whether or not melting is necessary for bonding; in view of the overall observations, melting does not seem to be a prerequisite for bonding.…”

Section: Window Of Deposition For Metallic Materialsmentioning

confidence: 99%

“…Subsequent studies by various other researchers confirm the role of ASI in bonding. Some studies have underlined the role of interfacial melting in bonding [64,[72][73][74].According to these studies, ASI may lead to partial melting for certain combinations of materials and impact conditions [75]. However, there is no consensus on whether or not melting is necessary for bonding; in view of the overall observations, melting does not seem to be a prerequisite for bonding.…”

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confidence: 99%

Cold spraying – A materials perspective

et al. 2016

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Cold spraying is a solid-state powder deposition process with several unique characteristics, allowing production of coatings or bulk components from a wide range of materials. The process has attracted much attention from academia and industry over the past two decades.The technical interest in cold spraying is twofold: first as a coating process for applications in surface technology, and second as a solid-state additive manufacturing process, offering an alternative to selective laser melting or electron beam melting methods. Moreover, cold spraying can be used to study materials behaviour under extremely high strain rates, high pressures and high cooling rates. The cold spraying process is thus considered to be relevant for various industrial applications, as well as for fundamental studies in materials science.This article aims to provide an overview of the cold spray process, the current understanding of the deposition mechanisms, and the related models and experiments, from a materials science perspective. IntroductionCold spraying (CS) is a solid-state material deposition technique, where micron-sized particles of a powder bond to a substrate as a result of high-velocity impact and the associated severe plastic deformation. Acceleration of particles to high velocities is obtained via expansion of a pressurised and (ironically) 'hot' gas through a diverging-converging nozzle.Despite heating the process gas -which is to provide higher acceleration of the gas and also to facilitate particle deformation through thermal softening -the feedstock remains in the solid state throughout the entire process; hence the name 'cold' spraying. This is to underline the contrast to conventional thermal spraying where particles are completely or partially molten upon impact onto the substrate. Alternative terminology includes cold gas spray, micro cold spray, cold gas dynamic spray, kinetic spray, supersonic particle deposition and metal powder application (MPA), all of which refer to the same principle of solid-state powder deposition as described above. CS is used for coating and repair. It is also used for additive manufacturing (AM) at relatively high deposition rates as compared to the methods based on selective laser or electron beam melting. The main advantage of CS is that it alleviates the problems associated with high temperature processing of materials, such as oxidation and unfavourable structural changes. It is possibly the only continuous method to produce bulk components of metastable materials that are available only in the powder form, e.g. as obtained from mechanical attrition or gas atomisation. The aim of the present paper is to provide an overview of CS from a materials perspective, particularly for a broader audience in materials research, e.g. with interest in dynamic phenomena, plasticity and phase transformations. In terms of application and properties, CS is perhaps best to be compared to thermal spraying processes, as in [24,25]. In view of relevant physical phenomena, however, CS is mos...

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“…Further increase in strain rate is experienced by materials under high speed manufacturing processes such as electromagnetic pulse forming [2][3][4] and electromagnetic pulse welding [5][6][7][8][9][10][11][12][13][14], vaporising foil actuator welding [15][16][17], friction stir processing [18][19][20], explosive welding [21], and other high speed impact conditions like explosion or cold spray processing [22,23]. Material characterisation at high strain rate also requires precise measurement techniques to capture the behaviour within the short duration of a mechanical test [1].…”

Section: Introductionmentioning

confidence: 99%

Suitability of the electromagnetic ring expansion test to characterize materials under high strain rate deformation

et al. 2016

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Abstract. Characterisation of materials under high strain rate is always challenging, and requires sophisticated apparatus. Magnetic pulse forming techniques can involve high strain rate deformation and the electromagnetic ring expansion test (ERET) is considered here to determine its suitability to characterise materials at high strain rate. The multi-physics and high speed nature of the process requires advanced numerical modelling techniques to gain insight and understanding of stress development when used as a material characterisation technique. In order to evaluate the suitability of the ERET to fully characterise the material behaviour at high strain rate, stress states were investigated using 3D coupled mechanical-electromagnetic simulations on a validated numerical model. The numerical simulations were performed in LS-Dyna ® with a modified Johnson-Cook (MJC) material model in this study. Albeit the preliminary results show the development of biaxial stress during the test, a shielding mechanism is proposed to eliminate the axial component of the stress on the rings. This study indicates that the ERET has a potential to be used for characterisation of the material parameters under the influence of high strain rate.

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An Experimental and Finite Element Study of Cold Spray Copper Impact onto Two Aluminum Substrates

Cited by 181 publications

References 42 publications

Effect of Gas Pressure and Temperature on Stereometric Properties of Al+Al2O3 Composite Coatings Deposited by LPCS Method

Effect of Gas Pressure and Temperature on Stereometric Properties of Al+Al2O3 Composite Coatings Deposited by LPCS Method

Cold spraying – A materials perspective

Suitability of the electromagnetic ring expansion test to characterize materials under high strain rate deformation

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