Numerical simulation of deformation behavior of Al particles impacting on Al substrate and effect of surface oxide films on interfacial bonding in cold spraying

Li, Wenya; Liao, Hanlin; Li, Chang-Jiu; Bang, Hee-Seon; Coddet, Christian

doi:10.1016/j.apsusc.2006.11.020

Cited by 143 publications

(57 citation statements)

References 18 publications

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“…It has been proposed that the first layer of the cold spray coating buildup (i.e., the deposition of particles onto the substrate) involves, first, substrate surface cratering and activation which removes any substrate surface oxide layers and thus allows a particle to bond with the surface ( Ref 6,7). The bonding mechanism is believed to be the result of an adiabatic shear instability at the interface during impact which occurs as a result of high strain rate deformation processes and creates a metal jet consisting of the particle and substrate material ( Ref 4,[8][9][10]. It is the formation of this metal jet which, it is proposed, results in the removal of the surface oxide layer and allows true metal to metal contact to be established.…”

Section: Introductionmentioning

confidence: 98%

Bonding Mechanisms in Cold Spraying: The Contributions of Metallurgical and Mechanical Components

et al. 2009

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The mechanism of bonding in cold spraying is still a matter of some debate. In this work, copper has been cold sprayed onto aluminium alloy substrates, the surfaces of which had been prepared in a variety of ways. The coating-substrate bonding was assessed via a novel intermetallic growth method along with adhesive pull-off testing, and related to the substrate preparation method. The bond strength has been rationalized in terms of a modified composite strength model, with two operative bonding mechanisms, namely (i) metallurgical bonding and (ii) mechanical interlocking of substrate material into the coating. In most cases, mechanical interlocking is able to account for a large proportion of the total bond strength, with metallurgical bonding only contributing significantly when the substrate had been polished and annealed prior to spraying. In addition, grit-blasting has been shown to significantly reduce the bond strength compared to other substrate preparation methods.

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Section: Introductionmentioning

confidence: 98%

Bonding Mechanisms in Cold Spraying: The Contributions of Metallurgical and Mechanical Components

et al. 2009

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“…However, there are still some fundamental problems to be revealed, such as the metal jetting and shear instability at the contact interfaces. On the other hand, the observed critical velocity was demonstrated to be influenced by the particle size (Ref 5), temperature (Ref [4][5][6]9), and its oxidation state ( Ref 6,[10][11][12] besides the mechanical properties of given particle and substrate materials ( Ref 1,2). Therefore, it is of significant importance to study the deformation behavior of cold spray particles upon impact.…”

Section: Introductionmentioning

confidence: 90%

“…Although the experiments have shown the effect of particle size on critical velocity (Ref 5), their simulation results obtained by the Lagrangian algorithm are believed to be unreasonable. The recent studies have shown the effect of oxide films on particle critical velocity ( Ref 6,10,12). Considering the fact that the small powders normally have higher oxygen contents than those of large powders (Ref 13), it is expected that the oxide films on particles surfaces is the main factor influencing critical velocity besides the material mechanical properties.…”

Section: Introductionmentioning

confidence: 98%

“…This is based on a two-step Eulerian solution algorithm. Two explicit finite element analysis (FEA) softwares, ABAQUS ( Ref 4,5,8) and LS-DYNA ( Ref 6,9,10) were also used to investigate the cold spray particle impacting behavior. These two explicit FEA programs are widely used to solve the engineering problems involving in nonlinear dynamic processes.…”

Section: Introductionmentioning

confidence: 99%

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Modeling Aspects of High Velocity Impact of Particles in Cold Spraying by Explicit Finite Element Analysis

Zhang

et al. 2009

J Therm Spray Tech

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In this study, an examination of cold spray particle impacting behavior using the ABAQUS/Explicit program was conducted for typical copper material (OFHC). Various combinations of calculation settings concerning element type, Arbitrary Lagrangian Eulerian adaptive meshing, contact interaction, material damage, etc., were examined with the main focus on the element excessive distortion and its effect on the resultant output. The effect of meshing size on the impact behavior was also clarified compared to the previous results obtained by using the LS-DYNA code. Some fundamental aspects on modeling of cold spray particle deformation are discussed.

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“…The particles were considered to be a solid sphere, and the calculation region for substrate was 5 times as the particles. More detailed information can be found elsewhere in the literature, e.g., Li et al [15]. (11) (12) E is the initial internal energy (J/kg•K).…”

Section: Interaction Between Particles In Cold Spray By Ls-dynamentioning

confidence: 99%

Study on the Growth of Holes in Cold Spraying via Numerical Simulation and Experimental Methods

Huang

Wang²,

et al. 2016

Coatings

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Cold spraying is a promising method for rapid prototyping due to its high deposition efficiency and high-quality bonding characteristic. However, many researchers have noticed that holes cannot be replenished and will grow larger and larger once formed, which will significantly decrease the deposition efficiency. No work has yet been done on this problem. In this paper, a computational simulation method was used to investigate the origins of these holes and the reasons for their growth. A thick copper coating was deposited around the pre-drilled, micro-size holes using a cold spraying method on copper substrate to verify the simulation results. The results indicate that the deposition efficiency inside the hole decreases as the hole become deeper and narrower. The repellant force between the particles perpendicular to the impaction direction will lead to porosity if the particles are too close. There is a much lower flattening ratio for successive particles if they are too close at the same location, because the momentum energy contributes to the former particle's deformation. There is a high probability that the above two phenomena, resulting from high powder-feeding rate, will form the original hole, which will grow larger and larger once it is formed. It is very important to control the powder feeding rate, but the upper limit is yet to be determined by further simulation and experimental investigation.

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Numerical simulation of deformation behavior of Al particles impacting on Al substrate and effect of surface oxide films on interfacial bonding in cold spraying

Cited by 143 publications

References 18 publications

Bonding Mechanisms in Cold Spraying: The Contributions of Metallurgical and Mechanical Components

Bonding Mechanisms in Cold Spraying: The Contributions of Metallurgical and Mechanical Components

Modeling Aspects of High Velocity Impact of Particles in Cold Spraying by Explicit Finite Element Analysis

Study on the Growth of Holes in Cold Spraying via Numerical Simulation and Experimental Methods

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