The Use of Particle/Substrate Material Models in Simulation of Cold-Gas Dynamic-Spray Process

Rahmati, Sadegh; Ghaei, Abbas

doi:10.1007/s11666-013-0051-4

Cited by 77 publications

(52 citation statements)

References 31 publications

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“…The Johnson-Cook plasticity model was used to determine the effects of strain hardening, strain rate hardening and thermal softening on the equivalent plastic deformation resistance. This model has been widely used to simulate the jetting phenomenon of particle impact during cold spraying [12,14,18,27,34,[57][58][59][60][61][62][63][64][65][66][67][68], despite its limitation at very high strain rates [57,69,70]. The equivalent plastic stress of the material is given as follows:…”

Section: Finite Element Modellingmentioning

confidence: 99%

Influence of Particle Velocity When Propelled Using N2 or N2-He Mixed Gas on the Properties of Cold-Sprayed Ti6Al4V Coatings

et al. 2018

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Cold-spraying is a relatively new low-temperature coating technology which produces coatings by the deposition of metallic micro-particles at supersonic speed onto target substrate surfaces. This technology has the potential to enhance or restore damaged parts made of light metal alloys, such as Ti6Al4V (Ti64). Particle deposition velocity is one of the most crucial parameters for achieving high-quality coatings because it is the main driving force for particle bonding and coating formation. In this work, studies were conducted on the evolution of the properties of cold-sprayed Ti64 coatings deposited on Ti64 substrates with particle velocities ranging from 730 to 855 m/s using pure N2 and N2-He mixture as the propellant gases. It was observed that the increase in particle velocity significantly reduced the porosity level from about 11 to 1.6% due to greater densification. The coatings’ hardness was also improved with increased particle velocity due to the intensified grain refinement within the particles. Interestingly, despite the significant differences in the coating porosities, all the coatings deposited within the velocity range (below and above critical velocity) achieved a high adhesion strength exceeding 60 MPa. The fractography also showed changes in the degree of dimple fractures on the particles across the deposition velocities. Finite element modelling was carried out to understand the deformation behaviour of the impacting particles and the evolutions of strain and temperature in the formed coatings during the spraying process. This work also showed that the N2-He gas mixture was a cost-effective propellant gas (up to 3-times cheaper than pure He) to deliver the high-quality Ti64 coatings.

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Section: Finite Element Modellingmentioning

confidence: 99%

Influence of Particle Velocity When Propelled Using N2 or N2-He Mixed Gas on the Properties of Cold-Sprayed Ti6Al4V Coatings

et al. 2018

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“…In AM, the component is developed by repeated deposition of coatings with respect to component cross-section. This technology enables the manufacturing of functional components in a single step, and the time and cost of the manufacturing does not depend on the complexity of the component [58,59]. The need for AM occurs due to its ability to (a) reduce manufacturing cost by eliminating production steps, hence small production is feasible, runs integrated functionality, (b) improved productivity, as tooling requirement is minimized, and (c) scrap waste by developing finished product directly from feedstock, and helping green manufacturing.…”

Section: Cold Spray In Additive Repair and Biofoulingmentioning

confidence: 99%

Development of Sustainable Cold Spray Coatings and 3D Additive Manufacturing Components for Repair/Manufacturing Applications: A Critical Review

2017

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This review article presents the findings of a comprehensive state-of-the-art literature review of the scientific and technological progress of the cold spray process in the field of repair/remanufacturing using the concept of additive manufacturing. A thorough study was conducted on the potential of this technology to form (a) both thin and thick coatings; (b) the ability to fabricate 3D freeform components in a single process, while benefiting from reduced residual stress level compared to conventional thermal spray coatings processes such as high velocity oxy-fuel (HVOF) or plasma spraying. A systematic overview of the process technology, particularly focusing on the suitability of ceramic-metallic (cermet) composite particles used as feedstock in the deposition was conducted; further elaboration was made pertinent to particle impact and bonding mechanisms during the deposition.

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“…It was noted by several authors ( Ref 11,12,[14][15][16][17] that this model fails to accurately predict material deformation at strain rates higher than 10 5 s À1 , due to the sharp increase in flow stress at strain rates typically found in Cold Spray. These are often greater than 10 7 s À1 ( Ref 11,14,18), which may explain the limitations of the JC model in successfully describing the particle-substrate behavior and predicting the deformation and adhesion properties. It has been demonstrated by Rahmati and Ghaei (Ref 14) that the particle impacts are more accurately predicted when using the PrestonTonks-Wallace (PTW) model than by using other models such as the Johnson-Cook, Modified Zerilli-Armstrong, Voyiadjis-Abed, Modified Khan-Huang-Liang, and GaoZhang model.…”

Section: Introductionmentioning

confidence: 98%

Finite Element Analysis and Failure Mode Characterization of Pyramidal Fin Arrays Produced by Masked Cold Gas Dynamic Spray

et al. 2015

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This work evaluates the shear strength of pyramidal fin arrays made from various feedstock materials (cylindrical aluminum, spherical nickel, and cylindrical stainless steel 304 powders) deposited on an Al6061-T6 substrate. Higher shear strength was measured for the nickel fin array followed by the stainless steel 304 and the aluminum arrays. Different failure modes were observed by inspecting the fracture surfaces under Scanning Electron Microscope. Deposition between the cold sprayed nickel and stainless fins was detected whereas dimples were noticed on the substrate between the fins when aluminum is used as the feedstock material. A numerical simulation of normal and angled impacts using the high strain rate Preston-Tonks-Wallace model was carried out in order to have a better understanding of the experimental results. The equivalent plastic strain (PEEQ) obtained from the finite element analysis at normal impact correlates with the different shear strengths measured experimentally. Furthermore, even if a higher PEEQ was observed for angled impacts compared to its normal collision counterpart, it is suggested that the particles may not bond because of the rotational restitution momentum caused by the tangential friction generated during angled impacts. This rotational restitution momentum was not detected for particle impacts normal to the substrate surface.

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The Use of Particle/Substrate Material Models in Simulation of Cold-Gas Dynamic-Spray Process

Cited by 77 publications

References 31 publications

Influence of Particle Velocity When Propelled Using N2 or N2-He Mixed Gas on the Properties of Cold-Sprayed Ti6Al4V Coatings

Influence of Particle Velocity When Propelled Using N2 or N2-He Mixed Gas on the Properties of Cold-Sprayed Ti6Al4V Coatings

Development of Sustainable Cold Spray Coatings and 3D Additive Manufacturing Components for Repair/Manufacturing Applications: A Critical Review

Finite Element Analysis and Failure Mode Characterization of Pyramidal Fin Arrays Produced by Masked Cold Gas Dynamic Spray

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