Particle size effects in metallic microparticle impact-bonding

Dowding, Ian; Hassani, Mostafa; Sun, Yuchen; Veysset, David; Nelson, Keith A.; Schuh, Christopher A.

doi:10.1016/j.actamat.2020.04.044

Cited by 57 publications

(23 citation statements)

References 35 publications

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“…Subsequently the local resistance of material to spallation decreases at higher temperatures. Dowding et al (186) used the proposed proportionality between the critical velocity and the spall strength (178,180) to predict the size effect and reported a reasonable agreement between the theory and the experimental measurements.…”

Section: Figure 16bmentioning

confidence: 92%

“…also shows that particle size can affect the critical velocity for bonding (115). Dowding et al (186) conducted a focused study of the size effect on the critical velocity for Al and Ti particles impacting matched material substrates. It was found that that as particle size increases by a factor of ~4, Al and Ti critical velocities decrease by ~25%.…”

Section: Figure 16bmentioning

confidence: 99%

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High-velocity micro-projectile impact testing

Veysset

Lee

Hassani

et al. 2021

Applied Physics Reviews

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High-velocity microparticle impacts are relevant to many fields from space exploration to additive manufacturing and can be used to help understand the physical and chemical behaviors of materials under extreme dynamic conditions. Recent advances in experimental techniques for single microparticle impacts have allowed fundamental investigations of dynamical responses of wide-ranging samples including soft materials, nano-composites, and metals, under strain rates up to 10 8 s -1 . Here we review experimental methods for high-velocity impacts spanning 15 orders of magnitude in projectile mass and compare method performances. Next, we present a review of recent studies using the laser-induced particle impact test technique comprising target, projectile, and synergistic target-particle impact response. We conclude by presenting the future perspectives in the field of high-velocity impact. FIG. 1. Impact testing techniques and applications, along with lines of constant characteristic strain rates. All-capital labels are associated with shaded regions of the same color.

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Section: Figure 16bmentioning

confidence: 92%

Section: Figure 16bmentioning

confidence: 99%

High-velocity micro-projectile impact testing

Veysset

Lee

Hassani

et al. 2021

Applied Physics Reviews

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“…Said calculator unveiled the particle impact velocity,

, critical impact velocity,

, critical velocity ratio (CVR), erosion velocity,

, and erosion velocity ratio (EVR) associated with the parameters in Table 1 , the D 50 for each powder reported in Figure 1 , and the UTS measured for each particle. From the CVR for each powder under the constant cold spray processing conditions, the recommended processing parameters were far from idealized, given that, as demonstrated by [ 50 ], a target particle impact velocity should result in a CVR that is equal to 1.3 times the critical velocity. For the present study, the cold spray parameters were held constant for the three different copper powder types.…”

Section: Resultsmentioning

confidence: 99%

Application of Mass Finishing for Surface Modification of Copper Cold Sprayed Material Consolidations

et al. 2022

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The surface roughness of additively manufactured (AM) components can have deleterious effects on the properties of the final part, such as corrosion resistance and fatigue life. Modification of the surface finish or parts produced by AM processes, such as cold spray, through methods such as mass finishing, can help to mitigate some of these issues. In this work, the surface evolution of as-produced copper cold sprayed material consolidations was studied through mass finishing. Three different copper powders attained by different production methods and of different sizes were used as feedstock. The surface topography of the cold spray deposits was measured as a function of the mass finishing time for the three copper cold spray samples and analyzed in terms of relative area and complexity, revealing an inverse correlation relating material removal rate and hardness/strength of the cold sprayed deposits. The material removal rate was also affected by the quality of the cold spray deposition, as defined by deposition efficiency (DE). Large initial drops in relative area and complexity are also likely due to the removal of loosely bonded powders at the start of mass finishing. Based on this study, the cold spray parameters that affect the rate of mass finishing have been explored.

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“…Most commonly, the cold spray process uses powders in the 5–100 μm range, with special cases using both smaller and larger particles [ 4 ]. Some work has been done on the effects of particle size on critical impact velocity for cold spray, but further studies are needed to understand both the ideal shape and morphology of powder for cold spray and their effects on consolidated cold spray properties [ 10 , 21 ].…”

Section: Resultsmentioning

confidence: 99%

“…Most commonly, the cold spray process uses powders in the 5-100 µm range, with special cases using both smaller and larger particles [4]. Some work has been done on the effects of particle size on critical impact velocity for cold spray, but further studies are needed to understand both the ideal shape and morphology of powder for cold spray and their effects on consolidated cold spray properties [10,21]. Figure 3 displays a low-magnification high-angle annular dark-field (HAADF) and EDS maps representative of the as-atomized Al 5056 internal microstructure; regions of magnesium solute segregation, dispersed iron intermetallic phases at the grain boundaries, and some Mg-Si phases at the grain boundaries are seen.…”

Section: Resultsmentioning

confidence: 99%

Characterization of Thermally Treated Gas-Atomized Al 5056 Powder

et al. 2020

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Aluminum 5056 is a work-hardenable alloy known for its corrosion resistance with new applications in additive manufacturing. A good understanding of the secondary phases in Al 5056 powders is important for understanding the properties of the final parts. In this study, the effects of different thermal treatments on the microstructure of Al 5056 powder were studied. Thermodynamic models were used to guide the interpretation of the microstructure as a function of thermal treatment, providing insight into the stability of different possible phases present in the alloy. Through the use of transmission electron microscopy (TEM) and energy-dispersive X-ray spectroscopy (EDS), combined with thermodynamic modeling, a greater understanding of the internal microstructure of Al 5056 powder has been achieved in both the as-atomized and thermally treated conditions. Evidence of natural aging within these powders was observed, which speaks to the shelf-life of these powders and the importance of proper treatment and storage to maintain consistent results.

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Particle size effects in metallic microparticle impact-bonding

Cited by 57 publications

References 35 publications

High-velocity micro-projectile impact testing

High-velocity micro-projectile impact testing

Application of Mass Finishing for Surface Modification of Copper Cold Sprayed Material Consolidations

Characterization of Thermally Treated Gas-Atomized Al 5056 Powder

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