SPH modeling and investigation of cold spray additive manufacturing with multi-layer multi-track powders

Zhang, Zhilang; Khalid, M.; Liu, Yangyang; Yuan, Ziming; Jiang, Qinghua; Liu, Wei

doi:10.1016/j.jmapro.2022.10.032

Cited by 14 publications

(1 citation statement)

References 42 publications

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“…This Lagrangian method has demonstrated its ability to simulate different physical problems involving large material deformation and mold filling encountered in highpressure die casting [23][24][25], low-pressure vacuum molding [26], and gravity permanent mold casting [27,28], metal forging [29], additive manufacturing [30][31][32][33], cold spray [34,35], thermal spray [36,37], machining [38,39], as well as in high-pressure plastic [40][41][42] or composite injection molding [43]. Despite its promising range of applications, SPH still suffers from key issues that need to be addressed in order to improve its readiness level in order to facilitate its percolation towards other industrial applications.…”

Section: Introductionmentioning

confidence: 99%

Smoothed Particle Hydrodynamics Approach for Simulation of Non-Newtonian Flow of Feedstocks Used in Powder Injection Molding

Meiabadi,

Demers,

Dufresne

2023

Metals

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The present work aims to explore the ability to simulate flow patterns and the velocity field in the powder injection molding (PIM) process using the smoothed particle hydrodynamics (SPH) method. Numerical simulations were performed using the DualSPHysics platform. A feedstock formulated from 17-4 PH stainless steel powder (60 vol. % of powder) and a wax-based binder system was prepared to experimentally obtain its rheological properties that were implemented in DualSPHysics using two different viscosity models. The numerical simulations were calibrated, and then validated with real-scale injections using a laboratory injection press. During the calibration step, the feedstock flow momentum equation in the DualSPHysics code was modified and boundary friction coefficients at different injection rates were adjusted to create a frictional effect. During the validation step, these calibrated conditions were used to simulate the flow behavior into a more complex shape, which was compared with experimental measurements. Using an appropriate boundary friction factor, both the frictional effect of the boundaries and the stability of the numerical solution were taken into account to successfully demonstrate the ability of this meshless SPH method. The flow front length and feedstock velocity obtained in a complex cavity were satisfactorily predicted with relative differences of less than 15%.

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