Modeling Parameters for Finite Element Simulation of Residual Stress in Cold Spray and the Stress Evolution and Distribution

Fan, Xueling; Chi, Zonglin; Meng, Fanchao; Chu, Xin

doi:10.1007/s11666-023-01640-z

Cited by 3 publications

(2 citation statements)

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“…In previous works, researchers have endeavored to predict the residual stress characteristics and explored the influence of thickness on these attributes in cold spray coatings by employing numerical and experimental methodologies [17,18,24,28,29,31,[50][51][52][53][54][55][56][57][58][59][60][61][62]. Ghelichi et al [18] deposited pure aluminum and Al7075 powders on Al5052 substrate.…”

Section: Introductionmentioning

confidence: 99%

“…They studied the residual stress produced within several atomic distances of a grain of the structure. Meng et al [52] simulated one particle in two dimensions and multiple particles in two and three dimensions by considering the deposition and the interaction between particles using Eulerian 2D and 3D models. The simulations for multiple particles showed a similar trend to those obtained experimentally.…”

Section: Introductionmentioning

confidence: 99%

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Effect of Thickness on the Residual Stress Profile of an Aluminum Cold Spray Coating by Finite Element Analysis

Torres,

Fernandez

2024

Coatings

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This research investigates the influence of thickness on residual stress profiles in aluminum cold spray coatings using finite element analysis (FEA). Residual stress is a critical factor that impacts coating adhesion, fatigue life, and susceptibility to delamination in thermal spray processes. Despite its acknowledged importance, predictive analysis of these stresses on a layer-by-layer basis remains relatively unexplored. This study introduces an innovative numerical methodology to analyze the progression of residual stresses across various deposition efficiencies (10%, 40%, 60%, and 100%) and layer thicknesses, thereby enhancing predictive accuracy for cold spray coatings. The findings demonstrate that the number of deposited layers significantly affects residual stress profiles in both coatings and the substrate, with compressive residual stress predominating in the coatings and deeper tensile stress predominating in the substrate. Residual stress behavior near the last deposited layer aligns with the expected peening effect. Discrepancies in substrate stress distributions may arise from variations in deposition parameters and unconsidered temperature effects. While the model generally aligns with theoretical and some empirical data, observed discrepancies underscore the need for further validation. This study lays the groundwork for informed decision-making for cold spray processes by providing insights into stress management, thereby contributing to enhancing coating integrity and performance.

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