Simulation of Particle Interaction with Surface Microdefects during Cold Gas-Dynamic Spraying

Abstract

The cold gas-dynamic spray (CGDS) technique is utilized for repairing processes of a large number of metallic components in mechanical and process engineering, such as bridges or vehicles. Fine particles impacting on the component surface can be severely deformed and penetrate into the defects, filling and coating them, resulting in possible protection against corrosion or crack propagation. This work focuses on the investigation of the impact behavior of cold sprayed particles with the wall surface having microdefects in the form of cavities. The collision of fine single particles with the substrate, both made from AISI 1045 steel, was simulated with the finite element method (FEM) using the Johnson–Cook failure model. The impact phenomena of particles on different microdefect geometries were obtained and compared with the collision on a smooth surface. The particle diameter and defect were varied to investigate the influence of the size on the deformation behaviour. The different impact scenarios result in different temperature and stress distributions in the contact zone, penetration and deformation behavior during the collision.

Determination of Critical Velocity of Cold-Sprayed NiCoCrAlY Coating via Arbitary Lagrangian-Eulerian (ALE) Method of Finite Element Simulation

“…When the diameter is 50 µm, the maximum PEEQ increases in the range of 500~550 m/s and decreases at the velocity of 650 m/s. Studies [37,43,57] have further shown that when the particle size increases to a certain size, its critical velocity decreases. Larger particles are more likely to deposited when the velocity of particles with small size also decrease equally; due to their higher critical velocity than the corresponding critical velocity of large particles, small particles may not be able to deposit on the substrate.…”

Cold Spray Coatings of Complex Concentrated Alloys: Critical Assessment of Milestones, Challenges, and Opportunities

“…Metallurgical bonding has been observed using various microstructural characterization techniques [17,27,47,52,53,[55][56][57]. These include scanning and transmission electron microscopy [55,58,59] and various empirical models [48,56,57] have been developed to explain the mechanism. The schematic representation of the bonding mechanism of a typical cold spray process (tantalum particle on 4340 steel substrate) is given in Figure 6.…”

“…Metallurgical bonding has been observed using various microstructural characterization techniques [17,27,47,52,53,[55][56][57]. These include scanning and transmission electron microscopy [55,58,59] and various empirical models [48,56,57] have been developed to explain the mechanism.…”

“…Three main types of models are used to simulate the cold spray processes. These include the finite element-based models, constitutive equations, and models for describing the bonding at the particle-substrate and particle-particle interfaces [39,58]. A summary of the models and their applications to cold spray processes are highlighted.…”

Numerical thermomechanical analysis of high strain rate impact of micro particle

“…Most other simulations were performed using Johnson-Cook strain-rate plasticity model, for example, by Yokoyama (2006) and Mebdoua et al (Mebdoua, Fizi & Bouhelal, 2016), and the impact of a particle coming into contact at an angle by Li et al (2007). Simulations of a particle falling into a crack in material were performed by Aleksieieva et al (2022). An attempt to simulate the impact by using different plasticity models, that is, closer to experimental high strain rate results, was made by Razavipour and Jodoin (2021).…”