Parametric Study to Repair Leaks in Water Pipe Using the Low-Pressure Cold Spray Technique

Recently, the low-pressure cold spray (LPCS) technique has been used to fabricate superhydrophobic polymer coatings on metallic substrates, suggesting a significant potential in engineering applications. This study aims to design a spiral LPCS nozzle to coat the pipe’s inner wall with superhydrophobic polymer. The design goal is to achieve the maximum particle velocity in a confined (limited) space, assuming that the powder can enter the feeding tube through the Venturi effect. Achieving these two goals simultaneously using only computational fluid dynamics (CFD) simulation is challenging. Therefore, the CFD simulation was combined with the neural network (NN) method to design the new spiral nozzle. During training, the effects of the NN models and algorithms were investigated. The results showed that the feedforwardnet model combined with the trainbr or trainlm algorithm (from MATLAB 2016b software), presented a minimal error for particle velocity or gas flux prediction, respectively. The trained NN correlates the nozzle parameters (i.e., mean coil diameter, spring lift angle, and expansion ratio) and its performances (i.e., particle velocity and gas flux in the powder feeding tube). As a result, the optimal spiral nozzle was determined based on the design goal of maximum particle velocity and suitable gas flux in the powder feeding tube. Furthermore, the effect of each nozzle parameter on the particle velocity and gas flux in the powder feeding tube was analyzed. The cold spray experiment confirmed that the designed spiral nozzle could fabricate Perfluoroalkoxy alkane (PFA) coatings.

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Direct Copper Metallization of Carbon Fiber-Reinforced Thermoplastic Polymers for Lightning Strike Protection Using Low-Pressure Cold Spray

Saito,

Izumi,

Meng

et al. 2024

J Therm Spray Tech

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Metallizing polymer composite via cold spray is an attractive process for producing lightning strike protection (LSP) in composite-based aircraft. However, direct deposition of copper, the most common conductive metal, on carbon fiber-reinforced thermoplastic polymers (CFRTP) remains challenging due to the severe polymer erosion and carbon fiber fracture induced by cold-sprayed multi-particle impact. In this work, the copper direct deposition window was explored by varying copper particle size and operating gas temperature, which are primary parameters determining particle impact energy. Following this, a lightning strike test was performed to evaluate the protective effectiveness of the deposited copper coating in reducing damage to the underlying CFRTP substrate. It was revealed that fine copper particles approximately 5 µm in diameter are effective for direct deposition due to their minimal induction of polymer erosion. Sufficient heating of the particle spray area above the glass transition temperature promoted continuous coating formation. The lightning strike tests demonstrated that the cold-sprayed copper coating effectively protects the underlying CFRTP by acting as a major electric current path and a sacrificial protective layer. These findings highlight the promising potential of cold spray as a new LSP technology for polymer composite aircraft.

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Parametric Study to Repair Leaks in Water Pipe Using the Low-Pressure Cold Spray Technique

Cited by 5 publications

References 32 publications

The Effect of Water Film Surrounding the Deposited Particle on Bonding Area: A Numerical Study

The Effect of Water Film Surrounding the Deposited Particle on Bonding Area: A Numerical Study

Optimal Design of a Cold Spray Nozzle for Inner Wall Coating Fabrication by Combining CFD Simulation and Neural Networks

Direct Copper Metallization of Carbon Fiber-Reinforced Thermoplastic Polymers for Lightning Strike Protection Using Low-Pressure Cold Spray

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