Experimental and numerical study of residual stress evolution in cold spray coating

Ghelichi, R.; Bagherifard, Sara; MacDonald, Daniel W.; Fernández-Pariente, I.; Jodoin, B.; Guagliano, Mario

doi:10.1016/j.apsusc.2013.09.074

Cited by 82 publications

(36 citation statements)

References 25 publications

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“…A study performed by Yin et al, [11] using irregular particle reported that coating deposited with irregular particle shape shows higher coating porosity and worse bonding than coating deposited with spherical particle shape. A by Ghelichi et al, [12] also claimed a similar result by using different aluminium powders. Both studies provide strong evidence to the numerical simulation in this study.…”

Section: Resultssupporting

confidence: 68%

Numerical analysis of Al coating using different particle shape in LPCS

Yusof

Manap²,

Afandi³

2016

IOP Conf. Ser.: Earth Environ. Sci.

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Section: Resultssupporting

confidence: 68%

Numerical analysis of Al coating using different particle shape in LPCS

Yusof

Manap²,

Afandi³

2016

IOP Conf. Ser.: Earth Environ. Sci.

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“…There have been numerical studies of residual stress through multiple particle impact simulations, which confirm this view [143][144][145]. Theoretical evaluation of the residual stress is nevertheless not straightforward.…”

Section: Residual Stressmentioning

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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“…However, the temperature history of particles during deposition processing generates some residual tensile stress due to thermal effects [15,16]. Moreover, the severe impact deformation generates some residual compressive stress due to the kinetic effects [16][17][18][19]. The intensive plastic deformation of particles also decreases the ductility of coldsprayed coatings due to work hardening effects.…”

Section: Introductionmentioning

confidence: 96%