Simulation of Critical Velocity of Cold Spray Process with Different Turbulence Models

Singhal, Chirag; Murtaza, Qasim; Parvej,

doi:10.1016/j.matpr.2018.04.150

Cited by 15 publications

(3 citation statements)

References 17 publications

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“…The turbulence is modeled using a realizable k-ε turbulence model with enhanced wall treatment as it is widely accepted in cold spraying studies and accurately captures the compression effects of scCO 2 as a compressible fluid during flow [34,35].…”

Section: Numerical Calculation Methodsmentioning

confidence: 99%

Numerical Simulation of Flow Characteristics for Supercritical CO2-Sprayed Polyurethane Resin

Li,

Zhang,

Xiang

et al. 2024

Polymers

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Conventional paint spraying processes often use small molecule organic solvents and emit a large amount of volatile organic compounds (VOCs) that are highly toxic, flammable, and explosive. Alternatively, the spraying technology using supercritical CO2 (scCO2) as a solvent has attracted attention because of its ability to reduce VOC emissions, but the flow characteristics of coatings have not been thoroughly studied. Therefore, we numerically simulate the spraying process based on the actual process of scCO2 spraying polyurethane coatings by computational fluid dynamics (CFD). The effects of inlet pressure and volume fraction of scCO2 on the fluid motion parameters inside the nozzle as well as the atomization effect of droplets outside the nozzle are investigated. The simulated results show that a fluid with a large volume fraction of scCO2 will obtain a smaller density, resulting in a larger velocity and a larger distance for the spray to effectively spray. Higher coating content and bigger inlet pressures will result in higher discrete phase model (DPM) concentrations, and thus a bigger inlet pressure should be used to make the droplets more uniform across the 30° spray range. This study can provide theoretical guidance for the process of scCO2-sprayed polyurethane resin.

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Section: Numerical Calculation Methodsmentioning

confidence: 99%

Numerical Simulation of Flow Characteristics for Supercritical CO2-Sprayed Polyurethane Resin

Li,

Zhang,

Xiang

et al. 2024

Polymers

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“…The Johnson-Cook plastic material constitutive model [28][29][30] was used to obtain better simulation results. The Mie-Gruneisen state equation [31] was selected by considering the softening of materials due to temperature and the reinforcement of materials under great strain.…”

Section: Simulation Model and Settingsmentioning

confidence: 99%

Critical Velocity Prediction and Characterization of Bonding Types of High-Velocity, Air-Fuel-Sprayed Titanium Coating on Aluminum Alloys

Liang¹,

Zhou

Liu³

2022

Coatings

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This study established finite-element models via LS-DYNA software to predict the critical velocity of Ti spray particles under different collision velocities and preheating temperatures. Particle deformation, collision temperature, and bonding types of the Ti coating/Al substrate system were simulated. At the predicted critical velocity (650 m/s) and the corresponding preheating temperature (300 °C), the TC4 titanium coating was fabricated on a 6061 aluminum substrate by high-velocity air fuel (HVAF) spray. The coating’s microstructure and phase transition were analyzed by a scanning electron microscope (SEM) equipped with energy-dispersion X-ray spectroscopy (EDS) and transmission electron microscopy (TEM), revealing that critical velocity decreases with increasing particle velocity and preheating temperature. At 650 m/s, the coating was well-bonded to the matrix in metallurgical bonding type, and mechanical interlock and metallurgical bonding coexisted among particles. Experimental results show that the coating is characterized by the metallurgical bonding type, a fusion layer, and recrystallization, which verifies the simulated collision temperatures.

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“…Even though CS is young in the thermal coating family, the process has merits that distinguish it from other solid-state techniques [ 40 , 41 ], including the ability to (i) support a variety of ductile metals [ 42 ], (ii) provide high-density, high-hardness, cold-worked microstructure [ 10 ], (iii) retain properties of initial particle materials [ 43 ], (iv) avoid oxidation and undesirable phases [ 10 ], (v) work with highly dissimilar materials [ 44 ], (vi) achieve high deposition efficiency as compared to other thermal coating processes [ 45 ], (vii) spray thermally sensitive materials [ 30 , 43 ], and (viii) operate with high flexibility and precision control [ 40 ].…”

Section: Introduction and Overviewmentioning

confidence: 99%

Recent advances on bonding mechanism in cold spray process: A review of single-particle impact methods

Adaan-Nyiak

Tiamiyu

2022

Journal of Materials Research

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Cold spray (CS) processing is a layer-by-layer solid-state deposition process in which particles at a temperature below their melting point are launched to sufficiently high velocities to adhere to a substrate (and previously deposited particles), forming coatings/parts. Despite being in existence for over four decades, particle bonding mechanisms in the CS process are unclear due to the complex particle–particle/carrier gas interactions that obscure assessment. This review evaluates recent findings from single-particle impact approaches that circumvent these complexities and further provide new insights on bonding mechanisms. Theories on the evolution of oxide layer breakup and delamination, adiabatic shear instability, jetting, melting, and interface solid-state amorphization that contributes to bonding are assessed and carefully reviewed. Although there is a unified condition in which bonding sets on, this study shows that no singular theory explains bonding mechanism. Rather, dominant mechanism is a function of the prevailing barriers unique to each impact scenario. Graphical abstract

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Simulation of Critical Velocity of Cold Spray Process with Different Turbulence Models

Cited by 15 publications

References 17 publications

Numerical Simulation of Flow Characteristics for Supercritical CO2-Sprayed Polyurethane Resin

Numerical Simulation of Flow Characteristics for Supercritical CO2-Sprayed Polyurethane Resin

Critical Velocity Prediction and Characterization of Bonding Types of High-Velocity, Air-Fuel-Sprayed Titanium Coating on Aluminum Alloys

Recent advances on bonding mechanism in cold spray process: A review of single-particle impact methods

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