Particle-based simulation of cold spray: Influence of oxide layer on impact process

Hemeda, Ahmed A.; Zhang, Chi; Hu, Xiangyu; Fukuda, Daisuke; Cote, Danielle L.; Nault, Isaac; Nardi, Aaron; Champagne, Victor K.; Ma, Yanbao; Palko, James W.

doi:10.1016/j.addma.2020.101517

Cited by 19 publications

(17 citation statements)

References 54 publications

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“…Despite supersonic flow with high velocity, tin oxidized in the gas stream due to relatively small size particles [ 51 ]. It is well known that oxidation of metal powder increases critical velocity of single particles [ 52 , 53 ]. However, tin shows low value of both critical and erosion velocity in comparison to other metals [ 39 ].…”

Section: Resultsmentioning

confidence: 99%

High Power Impulse Magnetron Sputtering of In2O3/Sn Cold Sprayed Composite Target

2021

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High Power Impulse Magnetron Sputtering (HiPIMS) was used for deposition of indium tin oxide (ITO) transparent thin films at low substrate temperature. A hybrid-type composite target was self-prepared by low-pressure cold spraying process. Prior to spraying In2O3 and oxidized Sn powders were mixed in a volume ratio of 3:1. Composite In2O3/Sn coating had a mean thickness of 900 µm. HiPIMS process was performed in various mixtures of Ar:O2: (i) 100:0 vol.%, (ii) 90:10 vol.%, (iii) 75:25 vol.%, (iv) 50:50 vol.%, and (v) 0:100 vol.%. Oxygen rich atmosphere was necessary to oxidize tin atoms. Self-design, simple high voltage power switch capable of charging the 20 µF capacitor bank from external high voltage power supply worked as a power supply for an unbalanced magnetron source. ITO thin films with thickness in the range of 30–40 nm were obtained after 300 deposition pulses of 900 V and deposition time of 900 s. The highest transmission of 88% at λ = 550 nm provided 0:100 vol. % Ar:O2 mixture, together with the lowest resistivity of 0.03 Ω·cm.

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Section: Resultsmentioning

confidence: 99%

High Power Impulse Magnetron Sputtering of In2O3/Sn Cold Sprayed Composite Target

2021

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“…Moreover, CS is superior in terms of anti-corrosion, wear protection, and scratch resistance against the traditional coating methods . In addition, with the development of related technologies, CS has become a promising additive manufacturing process for state-of-the-art applications requiring improved electrical, mechanical, and chemical properties. , Besides, CS can produce various composite layers made of polymers and metals while saving time and cost. These layers not only become a single layer of the TENG but also constitute an automatic bonding system for each friction layer and electrode.…”

Section: Introductionmentioning

confidence: 99%

Enhanced Performance of Triboelectric Nanogenerators and Sensors via Cold Spray Particle Deposition

Kim

Akin

Yun

et al. 2022

ACS Appl. Mater. Interfaces

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In this study, a high-performance triboelectric nanogenerator (TENG) is developed based on cold spray (CS) deposition of composite material layers. Composite layers were fabricated by cold spraying of micron-scale tin (Sn) particles on aluminum (Al) and polytetrafluoroethylene (PTFE) films, which led to improved TENG performance owing to functionalized composite layers as friction layers and electrodes, respectively. As-sprayed tin composite layers not only enhanced the flow of charges by strong adhesion to the target layer but also formed a nano–microstructure on the surface of the layers, thereby increasing the surface area during friction. More importantly, the electricity generation performance was improved more than 6 times as compared to the TENG without CS deposition on it. From parametric studies, the TENG using the cold-sprayed composite layer produced an electrical potential of 1140 V for a simple structure with a 25.4 × 25.4 mm2 contact area. We also optimize the geometry and fabrication process of the TENG to increase the manufacturing efficiency while reducing the processing cost. The resultant sprayed layers and structures exhibited sustainable robustness by showing consistent electrical performance after the mechanical adhesion test. The proposed manufacturing approach is also applicable for processing three-dimensional (3D) complex layers owing to the technological convergence of a cold spray gun attached to a robotic arm, which makes possible to fabricate the 3D TENG. To elaborate, a composite layer having the shape of a 3D ball is produced, and the exercise status of the ball is monitored in real-time. The fabricated 3D ball using the TENG transmitted a distinguishable signal in real-time according to the state of the ball. The proposed TENG sensing system can be utilized as a self-powered sensor without the need of a battery, amplifier, and rectifier. The results of this study can potentially provide insights for the practical material design and fabrication of self-powered TENG systems.

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“…It is widely accepted that cold spray is a solid-state coating process, during) which the bonding is formed due to plastic deformation rather than heat. To date, numerous studies have been carried out to investigate the cold spray process and several bonding mechanisms were proposed, including adiabatic shear instability at the interface during deposition (Ref 2 , 10 , 11 ), development of interfacial instability which induces physical anchoring effect Ref 12 , 13 ), and fracture and removal of the surface oxide layer due to high-velocity impact and subsequent metal jet formation (Ref 14 , 15 ). Nonetheless, there remains contention on the exact bonding mechanism during cold spray (Ref 3 , 16 - 20 ).…”

Section: Introductionmentioning

confidence: 99%

“…This kind of interaction is activated only when the nodes of opposing bodies are within a certain distance. It is noted that recently another particle-based method, i.e., the smoothed-particle hydrodynamics (SPH) has also been proposed as a means to model CS deposition (Ref 15 ), in which metal-to-metal interface treatment was considered in a 2D SPH model. Our approach, however, differs from the SPH method in two main aspects.…”

Section: Introductionmentioning

confidence: 99%

Peridynamic Simulation of Particles Impact and Interfacial Bonding in Cold Spray Process

Ren

Song

2022

J Therm Spray Tech

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Cold spray has recently emerged as a promising new technology for various coating, additive manufacturing, and on-site repair needs. One key challenge underlying cold spray is the proper simulation of the deposition process, for which numerous numerical studies have been carried out, but often fail to consider the interfacial adhesion. In this study, a new numerical approach on the base of peridynamics (PD) was developed to incorporate interfacial interactions as a part of the constitutive model to capture deformation, bonding, and rebound of impacting particles in one unified framework. Two models were proposed to characterize the adhesive contacts, i.e., a long-range Lenard-Johns type potential and a force-stretch relation of the interface directly derived from fracture properties of the bulk material. Using copper as the sample material, the deformation behaviors simulated by the PD-based approach were found to compare well with those from benchmark finite element method simulations. It was further demonstrated that this PD-based approach allows flexibility to realize different deposition scenarios, such as particle-substrate bonding and separation, by modulating adhesion energies. The approach provides a new numerical framework for more realistic cold spray impact simulations.

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Particle-based simulation of cold spray: Influence of oxide layer on impact process

Cited by 19 publications

References 54 publications

High Power Impulse Magnetron Sputtering of In2O3/Sn Cold Sprayed Composite Target

High Power Impulse Magnetron Sputtering of In2O3/Sn Cold Sprayed Composite Target

Enhanced Performance of Triboelectric Nanogenerators and Sensors via Cold Spray Particle Deposition

Peridynamic Simulation of Particles Impact and Interfacial Bonding in Cold Spray Process

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