Effect of Particle Size on Ceramic Particle Content in Cold Sprayed Al-Based Metal Matrix Composite Coating

Zhao, Lijia; Tariq, Naeem ul Haq; Ren, Yupeng; Liu, Hanhui; Han, Rifei; Cui, Xinyu; Wang, Jiqiang; Xiong, Tao

doi:10.1007/s11666-022-01457-2

Cited by 16 publications

(9 citation statements)

References 42 publications

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“…In addition, the effect of the particle material type on the plastic strain will be briefly discussed. Prior to presenting these results, it is worth noting that the model developed in this study is challenging to experimentally validate with in situ deposition data given the small scale of the particles and pores [ 2 , 11 , 12 , 28 , 33 ], and high speeds of the impact deposition process [ 12 , 28 ]. Regardless, we attempt to demonstrate how our model aligns with previous published works.…”

Section: Resultsmentioning

confidence: 99%

“…In this study, the B

C particle diameter varies from 15, 25, to 40

m ( Table 3 ), and this is guided by the particle size in experimental studies of Zhao et al [ 33 ]. The substrate height (

) and radius (

) are chosen to be 75

m to avoid any possible wave reflection (i.e., estimated by using the elastic wave velocity equation, v

).…”

Section: Methodology and Model Configurationsmentioning

confidence: 99%

“…In this study, simulations are performed over the first 24 ns of impact, which is sufficient to allow for observed behavior to be completed; this also corresponds to before when the elastic wave is reflected from the rear of the substrate to return to the impact zone [ 69 ]). In addition, the pore shape is assumed to be spherical to simplify the simulation, and the pore diameters are selected to be 1, 2, 3, and 4

m. Pore depths are 0.1

–0.5

based on the observation made in microscopic images of Al/B

C composites from the literature [ 2 , 11 , 12 , 28 , 33 , 70 ]. Lastly, Figure 1 also demonstrates the meshed particle and substrate with refined areas near the contact region.…”

Section: Methodology and Model Configurationsmentioning

confidence: 99%

“…To date, limited studies have focused on exploring the effect of porosity on the mechanical properties and structural integrity of Al/B

C coatings [ 27 , 29 , 30 , 31 , 32 ]. In the literature, Zhao et al [ 33 ] systematically investigated the effect of B

C and Al feedstock particle size on the weight percentage of the B

C in the cold-sprayed Al/B

C coating, and they found the optimal particle size for Al and B

C was 15

m to maximize the volume fraction of the B

C particles (≈30%), and to achieve maximum deposition efficiency. In the recent study by Zhao et al [ 34 ], they examined the effect of the Al (metal matrix material) particle size on B

C retention and the tribological properties of an Al/B

C cold sprayed composite coating.…”

Section: Introductionmentioning

confidence: 99%

“…Moreover, other studies [ 12 , 21 ] have shown that hard ceramic particles (e.g., B

C) fragment more after deposition into softer materials (e.g., Al), resulting in interfacial gaps between the particles and substrate, and subsequently, increasing the porosity level. Building on these studies, our efforts in this study aimed at better understanding the role of the matrix porosity (the size and location of pores), particle sizes, and impact velocities on the resulting impact deposition and, by extension, the quality of Al/B

C coatings (i.e., particle retention [ 12 , 33 ]).…”

Section: Introductionmentioning

confidence: 99%

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

2023

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This study explores the role of porosity in the impact deposition of a ceramic-reinforced metal-matrix (i.e., Al/B4C) composite coating fabricated via cold spraying. The Johnson–Holmquist–Beissel constitutive law and the modified Gurson–Tvergaard–Needleman model were used to describe the high strain-rate behavior of the boron carbide and the aluminum metal matrix during impact deposition, respectively. Within a finite element model framework, the Arbitrary Lagrangian–Eulerian technique is implemented to explore the roles of reinforcement particle size and velocity, and pore size and depth in particle retention by examining the post-impact crater morphology, penetration depth, and localized plastic deformation of the aluminum substrate. Results reveal that some degree of matrix porosity may improve particle retention. In particular, porosity near the surface facilitates particle retention at lower impact velocities, while kinetic energy dominates particle retention at higher deposition velocities. Altogether, these results provide insights into the effect of deposition variables (i.e., particle size, impact velocity, pore size, and pore depth) on particle retention that improves coating quality.

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Section: Resultsmentioning

confidence: 99%

“…In this study, the B

C particle diameter varies from 15, 25, to 40

m ( Table 3 ), and this is guided by the particle size in experimental studies of Zhao et al [ 33 ]. The substrate height (

) and radius (

) are chosen to be 75

m to avoid any possible wave reflection (i.e., estimated by using the elastic wave velocity equation, v

).…”

Section: Methodology and Model Configurationsmentioning

confidence: 99%

m. Pore depths are 0.1

–0.5

based on the observation made in microscopic images of Al/B

C composites from the literature [ 2 , 11 , 12 , 28 , 33 , 70 ]. Lastly, Figure 1 also demonstrates the meshed particle and substrate with refined areas near the contact region.…”

Section: Methodology and Model Configurationsmentioning

confidence: 99%

“…To date, limited studies have focused on exploring the effect of porosity on the mechanical properties and structural integrity of Al/B

C coatings [ 27 , 29 , 30 , 31 , 32 ]. In the literature, Zhao et al [ 33 ] systematically investigated the effect of B

C and Al feedstock particle size on the weight percentage of the B

C in the cold-sprayed Al/B

C coating, and they found the optimal particle size for Al and B

C was 15

m to maximize the volume fraction of the B

C particles (≈30%), and to achieve maximum deposition efficiency. In the recent study by Zhao et al [ 34 ], they examined the effect of the Al (metal matrix material) particle size on B

C retention and the tribological properties of an Al/B

C cold sprayed composite coating.…”

Section: Introductionmentioning

confidence: 99%

“…Moreover, other studies [ 12 , 21 ] have shown that hard ceramic particles (e.g., B

C coatings (i.e., particle retention [ 12 , 33 ]).…”

Section: Introductionmentioning

confidence: 99%

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