Academic literature on the topic 'Cold kinetic deposition (cold spray)'
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Journal articles on the topic "Cold kinetic deposition (cold spray)"
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Koivuluoto, Heli, Andrea Milanti, Giovanni Bolelli, Jyrki Latokartano, Francesco Marra, Giovanni Pulci, Jorma Vihinen, Luca Lusvarghi, and Petri Vuoristo. "Structures and Properties of Laser-Assisted Cold-Sprayed Aluminum Coatings." Materials Science Forum 879 (November 2016): 984–89. http://dx.doi.org/10.4028/www.scientific.net/msf.879.984.
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In the cold spray process, solid particles impact on a surface with high kinetic energy, deform plastically and form a coating. This enables the formation of pure and dense coating structures. Even more, coating performance and deposition efficiency can be improved by assisting the process with a laser. Laser-assisted cold spraying (LACS) has shown its potential to improve coating properties compared with traditional cold spraying. In this study, coating quality improvement was obtained by using a co-axial laser spray (COLA) process which offers a new, cost-effective laser-assisted cold spray technique, for high-quality deposition and repair. In the COLA process, the sprayed surface is laser heated while particles hit the surface. This assists the better bonding between particles and substrate and leads to the formation of tight coating structures. This study focuses on the evaluation of the microstructural characteristics and mechanical properties (e.g., hardness and bond strength) of LACS metallic coatings.
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Yu, Hai Jiao, Yu Ya Wang, Jun Xue, and Zun Wang. "An Advanced Metal Deposition Technique-Kinetic Metallization." Materials Science Forum 817 (April 2015): 510–15. http://dx.doi.org/10.4028/www.scientific.net/msf.817.510.
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Kinetic metallization (KM) is a sonic cold spray metal deposition technique, which offers promise as a way to produce coatings with a wild range of thickness. It is a solid-state process, from which the obtained coating is oxide free, high compactness (the porosity ratio may less than 0.1%), and has a strong bonding with the matrix. KM now is extensively applied in many fields, such as part/structure dimensional repair, solar battery manufacture, corrosion resistance and protection, wear resistance, oxidation resistance, and polymer spray. The present work presented the elements and advantages of KM, related it with high velocity oxy-fuel (HVOF) and common cold spray (CS), and reviewed the progress of KM over the two decades. Finally, the further development of the KM was discussed.
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Lee, Jae Chul, Doo Man Chun, Sung Hoon Ahn, and Caroline S. Lee. "Material Properties of Thick Aluminum Coating Made by Cold Gas Dynamic Spray Deposition." Key Engineering Materials 345-346 (August 2007): 1097–100. http://dx.doi.org/10.4028/www.scientific.net/kem.345-346.1097.
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Cold gas dynamic spray is a relatively new coating process by which coatings can be produced without significant heating during the process. Cold gas dynamic spray is conducted by powder sprayed using supersonic gas jet, and generally called the kinetic spray or cold spray. Its low process temperature can minimize the thermal stress and also reduce the deformation of the substrate. In this study, thick or macro scale deposition was studied while most researches on cold-spray have focused on micro scale coating. Measured material properties of macro scale deposition layer showed that elastic modulus and hardness were lower and electrical resistivity was higher than those of reference substrate material. The main causes of changed material properties were investigated by FE-SEM (Field Emission Scanning Electron Microscope) and EDS (Energy Dispersive X-ray Spectrometer) data. In this result, porous micro structure generated by imperfect plastic deformation might cause decrease in elastic modulus and hardness of the deposition layer by cold spray, and oxidized Al particles increased the electrical resistivity.
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Bala, Niraj, Harpreet Singh, and S. Prakash. "An Overview of Cold Spray Technique." Materials Science Forum 561-565 (October 2007): 2419–22. http://dx.doi.org/10.4028/www.scientific.net/msf.561-565.2419.
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The Cold spray or cold gas dynamic spraying is the new progressive step in the direction of development of high kinetic energy coating processes. The cold spray is a method for coating substrates under atmospheric conditions. In this process micron sized solid particles are accelerated and transported to substrates by means of supersonic free jets. Upon impacting the substrates, particles stick to the surface and form coatings which possess very low porosity. The paper outlines the principles involved in cold spray method and the equipment used for the technique. The cold spray method is related to classical thermal spray methods but it has some interesting additional features, which has been discussed in the paper. A fundamental feature of cold spray method i.e. concept of critical velocity along with the plausible mechanism theory responsible for the deposition of coating has been discussed briefly. Successful applications of cold spray process and its environment friendly aspect has been elaborated. It is reported that well founded cold spray technology will be able to compete for a good market share of VPS/PVD coatings in various fields like power, electronic/electrical, biotechnology, turbines and other industries. The cold spray process is still primarily in the research and development stage and only now becoming commercially available, and has been accepted as a new and novel thermal spray technique mainly in developed countries. The technology has great potential for future research especially with reference to its application to real industrial solution.
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Koivuluoto, Heli, Jussi Larjo, Danilo Marini, Giovanni Pulci, and Francesco Marra. "Cold-Sprayed Al6061 Coatings: Online Spray Monitoring and Influence of Process Parameters on Coating Properties." Coatings 10, no. 4 (April 3, 2020): 348. http://dx.doi.org/10.3390/coatings10040348.
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Process optimization and quality control are important issues in cold spraying and coating development. Because the cold spray processing is based on high kinetic energy by high particle velocities, online spray monitoring of particle inflight properties can be used as an assisting process tool. Particle velocities, their positions in the spray jet, and particle size measurements give valuable information about spraying conditions. This, in turn, improves reproducibility and reliability of coating production. This study focuses on cold spraying of Al6061 material and the connections between particle inflight properties and coating characteristics such as structures and mechanical properties. Furthermore, novel 2D velocity scan maps done with the HW CS2 online spray monitoring system are presented as an advantageous powder and spray condition controlling tool. Cold spray processing conditions were similar using different process parameters, confirmed with the online spray monitoring prior to coating production. Higher particle velocities led to higher particle deformation and thus, higher coating quality, denser structures, and improved adhesions. Also, deposition efficiency increased significantly by using higher particle velocities.
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Spencer, Kevin, Daniel Fabijanic, and Ming Xing Zhang. "Cold Spray of Al-MMC Coatings on Magnesium Alloys for Improved Corrosion and Wear Resistance." Materials Science Forum 618-619 (April 2009): 377–80. http://dx.doi.org/10.4028/www.scientific.net/msf.618-619.377.
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Cold spray coatings are considered promising for surface protection of Mg alloys from wear and corrosion since the process temperature is low enough to avoid oxidation of the Mg or any adverse affects on artificial ageing heat treatments. A special version of cold spray known as Kinetic Metallization has been used to produce pure Al and Al alloy metal matrix composite (MMC) coatings on AZ91 Mg alloy substrates in the present work. This surface treatment produces dense coatings with high adhesive and cohesive strength, which have substantially higher hardness and wear resistance than the AZ91 substrate material. The influence of coating composition and subsequent heat treatment on wear and corrosion performance have been investigated, using pin-on-disc wear tests, salt spray testing and electrochemical polarisation techniques. The heat treatment of the cold spray coatings is compatible with the solutionising and T6 ageing heat treatment of AZ91Mg. The results show that cold spray deposition of MMC coatings is a simple and effective technique for improving the surface properties of Mg alloys, both in the as-cast and in the heat treated condition
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Oyinbo, Sunday Temitope, and Tien-Chien Jen. "Feasibility of numerical simulation methods on the Cold Gas Dynamic Spray (CGDS) Deposition process for ductile materials." Manufacturing Review 7 (2020): 24. http://dx.doi.org/10.1051/mfreview/2020023.
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The techniques of cold gas dynamic spray (CGDS) coating involve the deposition of solid, high speed micron to nano particles onto a substrate. In contrast to a thermal spray, CGDS does not melt particles to retain their physico-chemical properties. There have been many advantages in developing microscopic analysis of deformation mechanisms with numerical simulation methods. Therefore, this study focuses on four cardinal numerical methods of analysis which are: Lagrangian, Smoothed Particles Hydrodynamics (SPH), Arbitrary Lagrangian-Eulerian (ALE), and Coupled Eulerian-Lagrangian (CEL) to examine the Cold Gas Dynamic Spray (CGDS) deposition system by simulating and analyzing the contact/impact problem at deformation zone using ductile materials. The details of these four numerical approaches are explained with some aspects of analysis procedure, model description, material model, boundary conditions, contact algorithm and mesh refinement. It can be observed that the material of the particle greatly influences the deposition and the deformation than the material of the substrate. Concerning the particle, a higher-density material such as Cu has a higher initial kinetic energy, which leads to a larger contact area, a longer contact time and, therefore, better bonding between the particle and the substrate. All the numerical methods studied, however, can be used to analyze the contact/impact problem at deformation zone during cold gas dynamic spray process.
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W. J., W. J. "Effects of Metal Particles on Cold Spray Deposition onto Ti-6Al-4V Alloy via Abaqus/Explicit." Journal of Engineering Sciences 7, no. 2 (2020): E19—E25. http://dx.doi.org/10.21272/jes.2020.7(2).e4.
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Titanium alloy is the main structural material of the aerospace system component. About 75 % of titanium and titanium alloys in the world are used in the aerospace industry. Hence, it is of great significance to study the surface deposition characteristics by cold spraying technology, taking Ti-6Al-4V alloy as an example, smoothed particle hydrodynamics (SPH) method in Abaqus/Explicit was used to spray aluminum, Ti-6Al-4V, copper, tungsten alloy (W alloy) and titanium particles onto Ti-6Al-4V substrate. The simulation results show that the deposition effect is good over 600 m/s, and higher energy is obtained for Ti-6Al-4V particles with the same properties as the matrix. For aluminum, Ti-6Al-4V, copper, W alloy, and titanium particles with different properties, under the same initial speed condition, the greater the density of the material, the deeper the foundation pit. W Alloy has the largest initial kinetic energy, the deepest foundation pit, and better surface bonding performance. The aluminum particle has the smallest initial kinetic energy, the shallowest foundation pit. However, the deposition effect of multiple aluminum particles has not improved. The collision process’s kinetic energy is transformed into internal energy, frictional dissipation, and viscous dissipation. Besides, the internal energy is mainly plastic dissipation and strain energy. Therefore, it is recommended to use Ti-6Al-4V, copper, nickel, W alloy, and titanium particles for different occasions, such as Ti-6Al-4V substrate surface restorative and protective coatings. Pure aluminum particles are not recommended.
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Tului, Mario, Cecilia Bartuli, Alessia Bezzon, Angelo Luigi Marino, Francesco Marra, Susanna Matera, and Giovanni Pulci. "Amorphous Steel Coatings Deposited by Cold-Gas Spraying." Metals 9, no. 6 (June 12, 2019): 678. http://dx.doi.org/10.3390/met9060678.
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Cold-gas spray (CGS) deposition of amorphous steel coatings starting from a commercial feedstock powder containing boron, tungsten, and silicon was investigated. Microstructural characterization, carried out by X-ray diffraction (XRD), transmission electron microscopy, and backscattered electron diffraction (EBSD) analysis, confirmed the amorphous nature of deposited coatings. The amorphization phenomenon is related to high-strain/strain-rate deformation with shear instability caused by very high particle kinetic energy, with a mechanism that resembles the severe plastic deformation process. The CGS coatings were heat-treated at temperatures ranging from 650 to 850 °C to induce partial recrystallization. The effect of nanocrystal nucleation and growth on the hardness of the coatings was investigated, and the hardness of heat-treated samples was found to increase with respect to as-sprayed coatings, outperforming conventional high-velocity oxy-fuel (HVOF) deposits. Hardness was found to decrease after prolonged (<90 min) or higher temperature (>750 °C) exposures.
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Ogawa, Kazuhiro, and Takahiro Niki. "Repairing of Degraded Hot Section Parts of Gas Turbines by Cold Spraying." Key Engineering Materials 417-418 (October 2009): 545–48. http://dx.doi.org/10.4028/www.scientific.net/kem.417-418.545.
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Hot section parts of combined cycle gas turbines are susceptible to degradation due to high temperature creep, crack formation by thermal stress, and high temperature oxidation, etc. Thus, regularly repairing or replacing the hot section parts such as gas turbine blades is inevitable. For this purpose, revolutionary and advanced repair technologies for gas turbines have been developed to enhance reliability of the repaired parts and reduce the maintenance cost of the gas turbines. The cold spraying process, which has been studied as not only a new coating technology but also as a process for obtaining a thick deposition layer, is proposed as a potential repairing solution. The process results in little or no oxidation of the spray materials, so the surfaces stay clean, which in turn enables superior bonding. Since the operating temperature is relatively low, the particles do not melt and the shrinkage on cooling is very low. In this study, the cold spraying conditions were optimized by taking into account the particle kinetic energy and the rebound energy for application in repairing gas turbine blades. A high quality cold-sprayed layer is that which has lowest porosity; thus the spraying parameters were optimized to achieve low-porosity layer, which was verified by scanning electron microscopy (SEM).
Dissertations / Theses on the topic "Cold kinetic deposition (cold spray)"
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Sámel, Maroš. "Využití technologie studené kinetické depozice na materiálech používaných v elektrotechnice." Master's thesis, Vysoké učení technické v Brně. Fakulta elektrotechniky a komunikačních technologií, 2021. http://www.nusl.cz/ntk/nusl-442477.
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The purpose of this diploma thesis is to get a better understanding of cold kinetic deposition (cold spray), principles of functioning of this method followed by an evaluation of advantages and disadvantages of cold spray and its comparison to conventional thermal methods and a simple summary of the practical use of cold spray with respect to different materials. Next there is a summary of the properties and uses of frequently applied metals in electrical engineering, aluminium and copper, description of metal corrosion and an understanding of the diagnostic method of acoustic emission. In the practical part, a sample with copper cold spray coating on aluminium substrate was created. Following, this sample was split for corrosion tests, where the split samples were exposed to a corrosive environment for different times of exposure. The extent of corrosion degradation of the samples was evaluated by acoustic emission and metallographic analysis for corrosion-loaded samples for 100, 200 and 300 hours. In the end, an illustrative design of the application of the cold spray technology was created.
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Rech, S., A. Surpi, S. Vezzu, A. Patelli, A. Trentin, J. Glor, Jenny Frodelius, Lars Hultman, and Per Eklund. "Cold-spray deposition of Ti2AlC coatings." Linköpings universitet, Tunnfilmsfysik, 2013. http://urn.kb.se/resolve?urn=urn:nbn:se:liu:diva-92686.
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Ti2AlC coatings have been fabricated by cold-spray deposition. The microstructure evolution as a function of basic spray parameters temperature and pressure onto AA6060 aluminium alloy and 1.0037 steel substrates has been studied. Adherent and dense 50–80 μm thick Ti2AlC coatings were deposited on soft AA6060 substrates under gas temperature and pressure of 600 °C and 3.4 MPa, respectively, whilst comparable results were obtained on harder 1.0037 steel by using higher temperature (800 °C) and pressure (3.9 MPa).
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Pereira, de Magalhaes e. Couto Miguel. "Cold Spray Deposition of WC-Co Cermets." Doctoral thesis, Universitat de Barcelona, 2014. http://hdl.handle.net/10803/285313.
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The main subject of this Thesis is the production of hard, wear and corrosion resistant cermets tungsten carbide and cobalt cermets (WC-Co) with different contents in cobalt matrix, onto low carbon steels and aluminum alloy Al7075-T6 substrates, by means of Cold Gas Spray (CGS). The current state of the art for the deposition of WC-Co uses High Velocity Oxy-Fuel (HVOF) as the main technique. Understanding both techniques was also one of the keys points in this work.
A deep theoretical approach about the CGS process, in which no melting of the particles occurs, was made at first to gain a better comprehension about the behaviour of the powder particles when sprayed onto different substrates and therefore being able to produce good quality coatings.
The starting purpose of this doctoral Thesis was to produce WC-25, 17 and 12%Co coatings onto low carbon steel and Al7075-T6 substrates. Until the day, using nitrogen as the process gas, such coatings could not be produced with enough adhesion, thickness and wear and corrosion properties. These are the main characteristics sought by the industry in these coatings. In the end of this doctorate WC-Co coatings were obtained with excellent mechanical and electrochemical properties, adhesion to both low carbon steel and Al7075-T6 substrates. Besides, these properties were increased and improved when compared to the same WC-Co coatings obtained by HVOF conventional deposition technique.
Initial problems such as flowability of the powders, bad adherence to the substrate, poor coating quality and extremely low deposition efficiencies were resolved during the period of the Thesis.
Also, and taking advantage of the novel coatings and excellent properties obtained using the referred feedstock powders and substrates, the knowledge was transferred to the industry as a trade secret.En primer lugar, el objetivo principal de este trabajo de investigación fue proporcionar un nuevo método de deposición para depositar cermets de WC-Co. Esta nueva tecnología proporcionó nuevos recubrimientos sin ninguna descomposición de la microestructura del polvo inicial y por lo tanto la mejora de las presentes aplicaciones de WC-Co en la gran industria. La deposición de cermets de WC-Co resistentes al desgaste ha sido siempre una de las principales aplicaciones de las técnicas de proyección térmica convencionales como por ejemplo High Velocity Oxy-Fuel (HVOF). Las demandas de la industria en términos de producción y la necesidad y constante búsqueda de mejores propiedades mecánicas y electroquímicas conducen al objetivo principal y la motivación de esta tesis: la producción de nuevos y mejores recubrimientos de WC-Co sobre varios sustratos utilizando una técnica de deposición nueva, Cold Gas Spraying (CGS). El hecho de que antes de la publicación del primer artículo que nació de este trabajo de investigación no se había depositado previamente con éxito este tipo de materiales por CGS fue también uno de los principales puntos de motivación. Por esta razón, el lector encontrará, en la integridad del documento, los trabajos de investigación que fueron publicados durante estos años de programa de doctorado y cumplen los objetivos principales de esta tesis titulada "Deposición de cermets de WC-Co por Proyección Fría".
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Xie, Jing. "Simulation of cold spray particle deposition process." Thesis, Lyon, INSA, 2014. http://www.theses.fr/2014ISAL0044/document.
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La projection à froid est une technologie en plein essor pour le dépôt de matériaux à l'état solide. Le procédé de dépôt des particules par pulvérisation à froid est simulé par la modélisation de l'impact à haute vitesse de particules sphériques sur un substrat plat dans diverses conditions. Pour la première fois, nous proposons une approche numérique par couplage Euler-Lagrange (CEL) afin de résoudre ce problème à haute vitesse de déformation. Les capacités de l'approche numérique CEL pour la modélisation du processus de dépôt de projection à froid sont évaluées par une étude paramétrique de : la vitesse d'impact, la température initiale des particules, le coefficient de frottement et le choix des matériaux. Les résultats de la simulation à l'aide de l'approche numérique CEL sont en accord avec les résultats expérimentaux publiés dans la littérature. La méthode CEL est généralement plus précise et plus robuste dans des régimes de déformations élevées. Un nouveau modèle d'empilement de type CFC, inspiré de la structure cristalline, est construit afin d'étudier le taux de porosité des particules déposées et les contraintes résiduelles dans le matériau de substrat pour diverses conditions. Nous pouvons observer non seulement la géométrie 3D de porosités, mais aussi leur répartition et leur évolution pendant les impacts successifs. Pour les particules, une vitesse d'impact et une température initiale élevées, sont des avantages pour produire des revêtements denses par projection à froid. Des contraintes résiduelles de compression existent à l'interface entre les particules et le substrat. Ces dernières sont causées par les grandes amplitudes et vitesses de déformation plastique induites par le procédé. Un second modèle moins complexe pour la modélisation de l'impact multiple oblique a été créé afin de simuler l'érosion de surface. Une forte érosion de surface est le résultat : d'une plus grande vitesse d'impact, d'un coefficient de frottement élevé et d'un angle de contact réduite. Pour un matériau ductile comme le cuivre, il y a deux modes de rupture : le mode 1 de traction et le mode 2 de rupture par cisaillement. Le premier survient principalement en dessous de la surface du substrat et à la périphérie de impacts, tandis que le second intervient de manière prédominante à la surface des impacts. On observe quatre étapes lors de la propagation des fissures : la formation de porosités, de fissures, la croissance de ces dernières, puis une dernière étape de coalescence et rupture. Un critère simple, où la vitesse d'érosion est fonction de l'angle de contact et de la vitesse critique d'érosion lors d'un impact de vitesse normale , est proposé sur la base des résultats des simulations afin de prédire l'initiation de l'endommagement. La déformation plastique équivalente est également un paramètre clef pour identifier l'initiation de l'endommagement, une valeur critique de 1,042 a été trouvée dans notre étude pour le cuivreCold spray is a rapidly developing coating technology for depositing materials in the solid state. The cold spray particle deposition process was simulated by modeling the high velocity impacts of spherical particles onto a flat substrate under various conditions. We, for the first time, proposed the Couple Eulerian Lagrangian (CEL) numerical approach to solve the high strain rate deformation problem. The capability of the CEL numerical approach in modeling the Cold Spray deposition process was verified through a systematic parameter study, including impact velocity, initial particle temperature, friction coefficient and materials combination. The simulation results by using the CEL numerical approach agree with the experimental results published in the literature. Comparing with other numerical approaches, which are Lagrangian, ALE and SPH, the CEL analyses are generally more accurate and more robust in higher deformation regimes. Besides simulating the single particle impact problem, we also extended our study into the simulation of multiple impacts. A FCC-like particles arrangement model that inspired by the crystal structure was built to investigate the porosity rate and residual stress of deposited particles under various conditions. We observed not only the 3D profiles of voids, but also their distributions and developments during different procedures. Higher impact velocity and higher initial temperature of particles are both of benefit to produce a denser cold spray coating. The compressive residual stresses existed in the interface between the particle and substrate is mainly caused by the large and fast plastic deformation. Another simplified model for multiple impacts was created for the simulation of surface erosion. A severe surface erosion is the result of a high impact velocity, a high friction coefficient and a low contact angle. Two element failure models suitable for high-strain-rate dynamic problems were introduced in this study. For a ductile material as Copper, it followed two fracture modes in our study, which are tensile failure mode and shear failure mode. The former one mainly occurred beneath the substrate surface and the periphery of substrate craters, nevertheless the latter one was found predominately at the surface of craters. Four steps were found during the propagation of crack: void formation; crack formation; crack growth; coalescence and failure. A simple criterion equation was derived based on the simulation results for predicting the initiation of damage, which the erosion velocity v_{ero} is a function of contact angle and erosion velocity for normal impact v_{pi/2}. The equivalent plastic strain could also be a parameter for identifying the onset of damage, identified as being 1.042 for Copper in our study
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Leazer, Jeremy D. "Processing-microstructure-property relationships for cold spray powder deposition of Al-Cu alloys." Thesis, Monterey, California: Naval Postgraduate School, 2015. http://hdl.handle.net/10945/45887.
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Approved for public release; distribution is unlimitedThis thesis presents research on the cold gas-dynamic spray process applied to the deposition of aluminum-copper alloy coatings. Cold spray deposition is a process utilized to create corrosion protection coatings and to perform additive repair for aluminum structures. This thesis utilized a series of Al-Cu binary alloy powders, from 2–5 weight percent copper and characterized their chemistry and microstructure. The powders were deposited using the cold spray approach to study the systematic increase of the alloying agent on the deposition process and coating characteristics. Deposition efficiency, critical velocity, coating thickness, hardness, porosity, and microstructure were all characterized as functions of carrier gas pressure, carrier gas temperature and feedstock powder copper composition. This thesis has demonstrated that all of the aluminum copper powders utilized can be successfully deposited via the low-pressure cold spray process with helium as the carrier gas. The copper content of the powders has a direct effect on the volume fraction of Al2Cu intermetallics, and on the coating hardness, while having no measurable effect on critical velocity for deposition or the coating thickness per pass.
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Sabela, Jakub. "Struktura a mechanické vlastnosti nástřiku Ti-6Al-4V připraveného metodou Cold Spray." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2019. http://www.nusl.cz/ntk/nusl-400850.
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Diploma thesis deals in the first part with recent knowledge of cold spray, its mechanism and parameters of deposition, advanced coatings made by cold spray and their applications, knowledge of Ti-6Al-4V coatings and their heat treatment. Deposit of Ti- 6Al-4V powder was made by cold spray process. In experimental part, microstructure and mechanical properties of supplied and its heat treated material were observed and examined. Mechanical properties and microstructure remained unchanged by annealing at 600 °C as in the case of supplied material. Recrystallization occured in microstructure of and phases by annealing at 800 °C. Grains were emerged in microstructure and mechanical properties were decreased. Mechanical properties were improved by annealing at 900 °C due to quenching. Microstructure consists of and ’ phases. Mechanical properties were the worst for annealed material at 1000 °C because of coarsed grains. Material which was annealed at 800 °C, quenched and precipitation hardened had the best microstructure and mechanical properties.
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Delloro, Francesco. "Méthodes morphologique et par éléments finis combinées pour une nouvelle approche de la modélisation 3D du dépôt par projection dynamique par gaz froid (« cold spray »)." Thesis, Paris, ENMP, 2015. http://www.theses.fr/2015ENMP0017/document.
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L'objectif principal de cette étude était de réaliser une modélisation du procédé cold spray, fondée sur l'observation expérimentale et sur des modèles physiques capables de prédire la microstructure du dépôt en fonction de la morphologie de la poudre et des paramètres de projection. Pour y arriver, le travaux se sont organisés autour de trois axes principaux de recherche : caractérisation de la poudre en 3D, simulations d'impact par éléments finis et modélisation d'empilement. Un procédé innovant de caractérisation morphologique de la poudre en 3D, utilisant la microtomographie par rayons X, a été développé. Le traitement des images résultantes a permis d'isoler les particules individuelles, regroupées dans une bibliothèque 3D d'environ 18000 objets. Leur taille et forme ont été caractérisées quantitativement. La méthode de partitionnement des données dite « K-means » a été utilisée pour la répartition des particules en 7 classes de forme.Le deuxième axe de recherche portait sur la simulation d'écrasement des particules, par la méthode des éléments finis (logiciel Abaqus, approche lagrangienne). L'utilisation d'outils de maillage adaptés a permis de réaliser des simulations d'écrasement des particules réelles (en provenance de la bibliothèque 3D). L'automatisation de ces simulations visait la possibilité d'en effectuer en grand nombre mais, face aux problèmes de robustesse rencontrés, le nombre de simulations menées à bien fut limité.Le troisième axe de recherche portait sur le développement d'un modèle d'empilement itératif, fondé sur l'utilisation des résultats des simulations d'écrasement. Ce modèle a été mis en place en 2D par simplicité. Différentes implémentations ont été essayées mais leur développement ne fut pas suffisamment abouti pour l'application à des cas pratiques.La validation des modèles s'est limitée aux simulations d'impact par éléments finis. Les deux types de splats (Ta sur Cu et Ta sur Ta), exigeant de méthodes d'observation expérimentale différentes, ont été traités séparément. Les premiers ont pu être directement observés par microtomographie et regroupés dans une bibliothèque 3D des splats Ta sur Cu. Ensuite, ils ont été comparés, de façon statistique mais aussi individuellement, aux correspondants simulés sans qu'aucune divergence évidente n'apparaisse. Le cas des Ta sur Ta est, en revanche, compliqué du fait de l'homogénéité du système qui empêche l'utilisation directe de la microtomographie. Bien que différentes méthodes visant à apporter une couche du contraste entre particule et substrat aient été essayées, la construction d'une bibliothèque 3D des splats Ta sur Ta n'a pas été possible.L'optimisation des poudres (choix de la granulométrie et de la forme, en vue d'une application donnée) est une des utilisations envisagées pour le modèle d'empilement, ainsi que la simulation de la projection de poudres composites (métal et oxyde). L'inclusion dans le modèle des transformations de phase ouvrirait la porte de la famille de la projection plasma ou de la fabrication additive. Plus généralement, la philosophie derrière la modélisation d'empilement développée dans cette thèse peut être appliquée à tout procédé où l'apport de matière est fait à partir d'une « poudre » subissant une certaine transformation. Enfin, le couplage avec un modèle de comportement pourrait permettre l'estimation de certaines propriétés physiques (par exemple, les conductivités thermique et électrique), dépendant de la microstructure du dépôtThis study on the cold spray process aimed at achieving an original coating build-up model, capable of predicting the resulting microstructure as a function of powder morphology and process parameters. The work focused on three main interrelated subjects: 3D powder characterization, simulation of individual impacts on a flat substrate by the finite element method and deposition build-up modeling.An innovative method based on microtomographical observations was used for 3D characterization of the powder. Image analysis allowed to separate single powder particles and to gather them into a 3D collection containing approximatively 18 000 objects. Their size and shape were quantitatively measured. A cluster analysis method (K-means) was then applied to this data set to divide the particles into 7 classes based on their shape.The second main research topic consisted in performing particle impact simulations on a flat substrate by the finite element method (using the commercial software Abaqus). The use of dedicated meshing tools allowed to simulate the impact of real particles, as observed by microtomography. Scripting techniques were used to carry out a large number of these simulations but, due to limited robustness of the procedure, only few of them were successfully conducted.The third research area focused on the development of a deposition build-up model (in 2D to allow a simpler implementation). Data from finite element results were interpolated and used in an iterative simulation, where impacting particles were deposited one by one. Different approaches were tested but the development of the model could not be completed in the framework of this thesis.Model validation could be performed on finite element simulations. The two kinds of splats (Ta on Cu and Ta on Ta) were considered separately. Concerning the first, direct microtomographical imaging could be applied, due to the heterogeneity of materials. Splats were observed, individually separated and gathered in a 3D collection as done before with powder particles. Simulated and observed splats could then be compared on a statistical basis. No particular discrepancy was observed, confirming the impact simulation method used. The second kind of splats (Ta on Ta) was complicated by the homogeneity of the materials, preventing the use of microtomography. The deposition (before spraying) of a contrast layer between Ta substrate and Ta particle was tried by different techniques. The only method giving exploitable results was the chemical vapor deposition of a Fe layer onto the powder particles. However, the small number of adherent particles and the weak contrast obtained in the images prevented the use of the methods already applied to powder particles and Ta splats onto Cu.The optimization of powder granulometry and shape (towards a specific application) is one of the main expected applications of the deposition build-up model, together with the simulation of composite powders (typically, metal and oxide). The involvement of phase transformation phenomena into the model could extend its application to the whole family of thermal spray processes (plasma, HVOF, etc.) or to other additive manufacturing techniques. In general, the philosophy behind our modeling approach could be applied to every manufacturing/coating technique where the supply material is in powder form and undergoes a certain transformation during the process. Finally, the coupling of such a model with homogenization techniques would allow the prediction of macroscopic properties depending on deposit microstructure (e.g. thermal or electrical conductivity)
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Bolduc, Mathieu. "Deposition of Commercially Pure Titanium Powder Using Low Pressure Cold Spray and Pulsed Gas Dynamic Spray for Aerospace Repairs." Thesis, Université d'Ottawa / University of Ottawa, 2013. http://hdl.handle.net/10393/24249.
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The objective of this study is to investigate the feasibility of depositing 1.5 mm thick titanium coatings, as a repair method for aerospace Ti-6Al-4V substrates, using two new commercially available processes: Low Pressure Cold Spray (LPCS) and Pulsed Gas Dynamic Spray (PGDS). The coatings produced were examined and characterized by their porosity level, microhardness, adhesion strength, particle flattening ratio, wipe tests, fracture surface type and wear tests. Phases and chemical composition were determined using X-Ray diffraction analysis and energy dispersive spectroscopy, respectively. It was found that both spraying processes are capable of producing dense, hard and oxide-free coatings using specific parameters. Finally, as a first step towards repair implementation of these processes, damages were simulated on Ti-6Al-4V samples, which were successfully repaired with low porosity and high hardness levels. The feasibility of repairs was confirmed, the next step will consist in qualification testing to assess coating performances under real life application.
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Akhtar, Kareem. "A Numerical Study of Supersonic Rectangular Jet Impingement and Applications to Cold Spray Technology." Diss., Virginia Tech, 2015. http://hdl.handle.net/10919/71711.
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Particle-laden supersonic jets impinging on a flat surface are of interest to cold gas-dynamic spray technology. Solid particles are propelled to a high velocity through a convergent-divergent nozzle, and upon impact on a substrate surface, they undergo plastic deformation and adhere to the surface. For given particle and substrate materials, particle velocity and temperature at impact are the primary parameters that determine the success of particle deposition. Depending on the particle diameter and density, interactions of particles with the turbulent supersonic jet and the compressed gas region near the substrate surface can have significant effects on particle velocity and temperature. Unlike previous numerical simulations of cold spray, in this dissertation we track solid particles in the instantaneous turbulent fluctuating flow field from the nozzle exit to the substrate surface. Thus, we capture the effects of particle-turbulence interactions on particle velocity and temperature at impact.
The flow field is obtained by direct numerical simulations of a supersonic rectangular particle-laden air jet impinging on a flat substrate. An Eulerian-Lagrangian approach with two-way coupling between solid particles and gas phase is used. Unsteady three-dimensional Navier-Stokes equations are solved using a six-order compact scheme with a tenth-order compact filter combined with WENO dissipation, almost everywhere except in a region around the bow shock where a fifth-order WENO scheme is used. A fourth-order low-storage Runge-Kutta scheme is used for time integration of gas dynamics equations simultaneously with solid particles equations of motion and energy equation for particle temperature. Particles are tracked in instantaneous turbulent jet flow rather than in a mean flow that is commonly used in the previous studies. Supersonic jets for air and helium at Mach number 2.5 and 2.8, respectively, are simulated for two cases for the standoff distance between the nozzle exit and the substrate. Flow structures, mean flow properties, particles impact velocity and particles deposition efficiency on a flat substrate surface are presented. Different grid resolutions are tested using 2, 4 and 8 million points. Good agreement between DNS results and experimental data is obtained for the pressure distribution on the wall and the maximum Mach number profile in wall jet. Probability density functions for particle velocity and temperature at impact are presented. Deposition efficiency for aluminum and copper particles of diameter in the range 1 micron to 40 microns is calculated.
Instantaneous flow fields for the two standoff distances considered exhibit different flow characteristics. For large standoff distance, the jet is unsteady and flaps both for air (Mach number 2.5) and for helium (Mach number 2.8), in the direction normal to the large cross-section of the jet. Linear stability analysis of the mean jet profile validates the oscillation frequency observed in the present numerical study. Available experimental data also validate oscillation frequency. After impingement, the flow re-expands from the compressed gas region into a supersonic wall jet. The pressure on the wall in the expansion region is locally lower than ambient pressure. Strong bow shock only occurs for small standoff distance. For large standoff distance multiple/oblique shocks are observed due to the flapping of the jet.
The one-dimensional model based on isentropic flow calculations produces reliable results for particle velocity and temperature. It is found that the low efficiency in the low-pressure cold spray (LPCS) compared to high-pressure cold spray (HPCS) is mainly due to low temperature of the particles at the exit of the nozzle. Three-dimensional simulations show that small particles are readily influenced by the large-scale turbulent structures developing on jet shear layers, and they drift sideways. However, large particles are less influenced by the turbulent flow. Particles velocity and temperature are affected by the compressed gas layer and remain fairly constant in the jet region. With a small increase in the particles initial temperature, the deposition efficiency in LPCS can be maximized. There is an optimum particle diameter range for maximum deposition efficiency.Ph. D.
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Tsaknopoulos, Kyle Leigh. "Computational Thermodynamic and Kinetic Modeling and Characterization of Phase Transformations in Rapidly Solidified Aluminum Alloy Powders." Digital WPI, 2019. https://digitalcommons.wpi.edu/etd-dissertations/516.
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Cold Spray is a solid-state additive manufacturing process that uses metallic feedstock powders to create layers on a substrate through plastic deformation. This process can be used for the repair of mechanical parts in the aerospace industry as well as for structural applications. Aluminum alloy powders, including Al 6061, 7075, 2024, and 5056, are typically used in this process as feedstock material. Since this process takes place all in the solid state, the properties and microstructure of the initial feedstock powder directly influence the properties of the final consolidated Cold Spray part. Given this, it is important to fully understand the internal powder microstructure, specifically the secondary phases as a function of thermal treatment. This work focuses on the understanding of the internal microstructure of Al 6061, 7075, 2024, and 5056 through the use of light microscopy, scanning electron microscopy, transmission electron microscopy, energy dispersive x-ray spectroscopy, electron backscatter diffraction, and differential scanning calorimetry. Thermodynamic models were used to predict the phase stability in these powders and were calibrated using the experimental results to give a more complete understanding of the phase transformations during thermal processing.
Books on the topic "Cold kinetic deposition (cold spray)"
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Champagne, D. The Cold Spray Materials Deposition Process. Woodhead Publishing Ltd, 2007.
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Champagne, Victor K. The cold spray materials deposition process. Woodhead Publishing Limited, 2007. http://dx.doi.org/10.1533/9781845693787.
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Champagne, Victor, ed. The Cold Spray Materials Deposition Process. CRC Press, 2007. http://dx.doi.org/10.1201/9781439824122.
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Champagne:, Victor K. The Cold Spray Materials Deposition Process: Fundamentals and Applications (Woodhead Publishing in Materials). CRC, 2007.
Find full textBook chapters on the topic "Cold kinetic deposition (cold spray)"
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Henao, John, and Mala M. Sharma. "Characterization, Deposition Mechanisms, and Modeling of Metallic Glass Powders for Cold Spray." In Cold-Spray Coatings, 251–72. Cham: Springer International Publishing, 2017. http://dx.doi.org/10.1007/978-3-319-67183-3_8.
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Bhattiprolu, Venkata Satish, and Luke N. Brewer. "Laser Assisted Cold Spray Deposition." In Materials Forming, Machining and Tribology, 177–96. Cham: Springer International Publishing, 2020. http://dx.doi.org/10.1007/978-3-030-42756-6_6.
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Astarita, Antonello, Luca Boccarusso, Luigi Carrino, Massimo Durante, Alessia Serena Perna, and Antonio Viscusi. "Cold Spray Deposition on Polymeric and Composite Substrates." In Materials Forming, Machining and Tribology, 87–128. Cham: Springer International Publishing, 2020. http://dx.doi.org/10.1007/978-3-030-42756-6_4.
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Rein, Martin, Ali Erdi-Betchi, and Konstantin V. Klinkov. "Transonic Flow Phenomena of the Cold Spray Deposition Process." In IUTAM Symposium Transsonicum IV, 177–82. Dordrecht: Springer Netherlands, 2003. http://dx.doi.org/10.1007/978-94-010-0017-8_28.
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Lee, Jae Chul, Doo Man Chun, Sung Hoon Ahn, and Caroline S. Lee. "Material Properties of Thick Aluminum Coating Made by Cold Gas Dynamic Spray Deposition." In The Mechanical Behavior of Materials X, 1097–100. Stafa: Trans Tech Publications Ltd., 2007. http://dx.doi.org/10.4028/0-87849-440-5.1097.
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Moridi, A., S. M. Hassani-Gangaraj, M. Guagliano, and S. Vezzu. "Effect of Cold Spray Deposition of Similar Material on Fatigue Behavior of Al 6082 Alloy." In Fracture and Fatigue, Volume 7, 51–57. Cham: Springer International Publishing, 2013. http://dx.doi.org/10.1007/978-3-319-00765-6_8.
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Shiva, S., L. Michaux, A. Cockburn, D. Hopkinson, I. A. Palani, C. P. Paul, and W. O’ Neill. "Development of CuAlNi Shape Memory Alloy Structures Using Cold Spray Deposition Technique with Laser Remelting." In Materials Forming, Machining and Tribology, 197–218. Cham: Springer International Publishing, 2020. http://dx.doi.org/10.1007/978-3-030-42756-6_7.
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Msolli, Sabeur, Zhi-Qian Zhang, Junyan Guo, Sridhar Narayanaswamy, Reddy Chilla Damodara, Zheng Zhang, Jisheng Pan, Boon Hee Tan, and Qizhong Loi. "An Automated Deposition Procedure for Cold Spray Additive Manufacturing Process Modeling Based on Finite Element Simulation." In Lecture Notes in Mechanical Engineering, 133–43. Singapore: Springer Singapore, 2019. http://dx.doi.org/10.1007/978-981-15-0054-1_14.
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Nélias, Daniel, Jing Xie, Hélène Walter-Le Berre, Yuji Ichikawa, and Kazuhiro Ogawa. "Simulation of the Cold Spray Deposition Process for Aluminum and Copper using Lagrangian, ALE and CEL Methods." In Thermomechanical Industrial Processes, 321–58. Hoboken, USA: John Wiley & Sons, Inc., 2014. http://dx.doi.org/10.1002/9781118578759.ch7.
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Verdi, Davide, Qizhong Loi, Boon Hee Tan, and Alin Patran. "Feasibility Tests on Directed Laser Deposition and Cold Spray Coatings Applied in Series for Different Industrial Applications." In Lecture Notes in Mechanical Engineering, 134–37. Singapore: Springer Singapore, 2021. http://dx.doi.org/10.1007/978-981-16-5763-4_29.
Full textConference papers on the topic "Cold kinetic deposition (cold spray)"
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Celeste, Geoffrey, Vincent Guipont, and Djamel Missoum-Benziane. "Investigation of Agglomerated and Porous Ceramic Powders Suitable for Cold Spray." In ITSC2021, edited by F. Azarmi, X. Chen, J. Cizek, C. Cojocaru, B. Jodoin, H. Koivuluoto, Y. C. Lau, et al. ASM International, 2021. http://dx.doi.org/10.31399/asm.cp.itsc2021p0139.
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Abstract Cold gas spraying is a solid-state deposition process developed for metallic powders as feedstock materials. For ceramic materials; such low temperature-high velocity kinetic process is still questionable but could have interesting advantages. In the CERASOL project (ANR-19-CE08-0009); the nature and the architecture of porous ceramic powders involving agglomerated sub-micrometric grains are investigated. To that purpose; three oxide ceramics powders (alumina; zirconia and yttria) have been prepared for cold spray. These powders were analyzed in order to assess their architecture (composition; particle size; porosity; density; crystallite sizes…). Preliminary cold spray experiments were carried out implementing velocities measurements for various stand-off distances and spraying of coupons with line experiments. The characteristics of the deposited layers have been examined by SEM and XRD in order to discuss the role of the powder architecture on the impact behavior of the nanostructured agglomerated particles. The role of the gas stream that affects the kinetic and the trajectory of the particles are also discussed.
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Ren, Baihua, and Jun Song. "Peridynamic Simulation of Particles Impact and Interfacial Bonding in Cold Spray Process." In ITSC2021, edited by F. Azarmi, X. Chen, J. Cizek, C. Cojocaru, B. Jodoin, H. Koivuluoto, Y. C. Lau, et al. ASM International, 2021. http://dx.doi.org/10.31399/asm.cp.itsc2021p0396.
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Abstract Recently, cold spray (CS) technology has attracted extensive interest as an alternative to thermal spray methods to build a coating, which uses high kinetic energy solid particles to impact and adhere to the substrate. To date, numerous numerical studies have been carried out to investigate the deposition processes and associated mechanisms during multiple particle impact in CS. However, in the commonly used numerical techniques, the individual powder particles are often treated separately from one another, thus fail to properly consider the adhesion mechanisms during deposition. In this study, we propose a new numerical approach on base of peridynamics (PD), which incorporates interfacial interactions as a part of constitutive model to capture deformation, bonding and rebound of impacting particles in one unified framework. Two models are proposed to characterize the adhesive contacts: a) a long-range Lenard-Johns type potential that reproduce the mode I fracture energy by suitable calibrations, and b) a force - stretch relation of interface directly derived from the bulk materials mode I fracture simulations. The particle deformation behavior modeled by the peridynamic method compares well with the benchmark finite element method results, which indicates the applicability of the peridynamic model for CS simulation. Furthermore, it is shown that the adhesive contact models can accurately describe interfacial bonding between the powder particles and substrate.
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Gao, Hong, Liangju Zhao, Danling Zeng, and Lijuan Gao. "Molecular Dynamics Simulation of Au Cluster Depositing on Au Surface in Cold Gas Spray." In 2007 First International Conference on Integration and Commercialization of Micro and Nanosystems. ASMEDC, 2007. http://dx.doi.org/10.1115/mnc2007-21609.
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Cold gas spray is a relatively new coating technique by which coatings can be formed without significant heating of the sprayed powder. In contrast to the conventional thermal spray processes, such as flame, arc, and plasma spraying, in cold spraying there is no melting of particles prior to impact on the substrate. In cold spray, particles are accelerated to a very high velocity by a flowing gas with supersonic speed and the temperature of spray particles is much lower than its melting point. However, being accomplished in so short an interval, the impact and deposition processes are difficult to be observed by experimental ways. Using molecular dynamics simulation, the deposition of nano-scale Au clusters on Au (001) surface was studied. The many-body potential is used to simulate the interatomic force between the atoms. By taking “snapshot”, the impact, deposition process and the final appearances of the cluster and the substrate were observed directly. It is found that both the substrate and the cluster deform and lose the crystalline structure. But after reconstruction and relaxation, both of them recover the crystalline structure. By calculating the temperatures of the substrate and the local area influenced by impinging, it is found that the melt phenomenon occurs during impact and deposition, whereas the temperature of the rest region of the substrate is still below the melt point. In addition, the influence factors on deposition, such as incident velocity and the size of the cluster, are discussed in the paper. Simulation results show that the higher incident velocity or the larger size of the cluster could result in stronger interaction between the substrate and the cluster owing to the higher kinetic energy of the cluster.
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Yu, Minjae, Hiroki Saito, Chrystelle Bernard, Yuji Ichikawa, and Kazuhiro Ogawa. "Influence of the Low-Pressure Cold Spray Operation Parameters on Coating Properties in Metallization of Ceramic Substrates Using Copper and Aluminum Composite Powder." In ITSC2021, edited by F. Azarmi, X. Chen, J. Cizek, C. Cojocaru, B. Jodoin, H. Koivuluoto, Y. C. Lau, et al. ASM International, 2021. http://dx.doi.org/10.31399/asm.cp.itsc2021p0147.
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Abstract The low-pressure cold spray (LPCS) technique could be an attractive method for copper metallization of ceramic substrates to power module applications due to its one-step quick and lowtemperature process. However; manufacturing pure copper coating on a ceramic substrate by LPCS is still challenging due to its low deposition efficiency and poor adhesion strength. Our previous study successfully demonstrated the possibility of obtaining a zirconia substrate's metallization by using a feedstock powder mixture of copper and aluminum. However; the copper content in the coating was not high enough for power module applications. Therefore; in this study; we aim to improve the copper content in the coating layer composed of the composite powder deposited by LPCS on alumina and zirconia substrates. The influence of the gas pressure and standoff distance on the copper content and coating thickness are evaluated. The coating build-up with a high copper content and thickness is highly dependent on the kinetic energy of particles; enhanced by high gas pressure and short stand-off distance.
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Karthikeyan, J., C. M. Kay, J. Lindeman, R. S. Lima, and C. C. Berndt. "Cold Spray Processing of Titanium Powder." In ITSC 2000, edited by Christopher C. Berndt. ASM International, 2000. http://dx.doi.org/10.31399/asm.cp.itsc2000p0255.
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Abstract Oxygen-free titanium coatings are at present produced using vacuum plasma spray systems. The cold spray process can produce titanium coatings in atmospheric air at reduced cost. Variations of the deposition efficiency as well as the coating characteristics with various process parameters were studied. Results show that the deposition efficiency drops drastically below a critical temperature. The parameters which affect the jet velocity; viz., the type of gas and the nozzle geometry have maximum effect on the process deposition efficiency. Sprayed coatings were porous and exhibited a low modulus and high hardness. Post processing of the coating by machining produced dense, strong and hard coatings. Key words: Cold-Spray, Titanium, Oxidation.
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Perez, Lorena, Jake Colburn, Luke N. Brewer, Michael Renfro, and Tim McKechnie. "Cold Spray Deposition of Heat-Treated Inconel 718 Powders." In ITSC2021, edited by F. Azarmi, X. Chen, J. Cizek, C. Cojocaru, B. Jodoin, H. Koivuluoto, Y. C. Lau, et al. ASM International, 2021. http://dx.doi.org/10.31399/asm.cp.itsc2021p0171.
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Abstract In this work; Inconel 718 gas-atomized powder was successfully heat treated over the range of 700-900°C. As-atomized and as-heat treated powders were cold sprayed with both nitrogen and helium gasses. Cold spray of high strength materials is still challenging due to their resistance to particle deformation affecting the resulting deposit properties. Powder heat treatment to modify its deformation behavior has recently been developed for aluminum alloy powders; however; there is no literature reported for Inconel 718 powders. The microstructural evolution of the powder induced by the heat treatment was studied and correlated with their deformation behavior during the cold spray deposition. Deposits sprayed with heat-treated powders at 800 and 900 °C and nitrogen showed less particle deformation and higher porosity as compare to as-atomized deposit associated to the presence of delta phase in the powders precipitated by the heat treatment. In contrast; deposits sprayed with helium using both powder conditions; as-atomized and as heat-treated powders; showed high particle deformation and low porosity indicating that the type of gas has a greater effect on the particle deformation than the delta phase precipitated in the heat-treated powders. These results contribute to understanding the role of powder microstructure evolution induced by heat treatment on the cold spray deposits properties.
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Bhattacharya, Sourin, Artur Lutfurakhmanov, Justin M. Hoey, Orven F. Swenson, and Rob Sailer. "Micro Cold Spray Direct Write Process." In ASME 2012 International Mechanical Engineering Congress and Exposition. American Society of Mechanical Engineers, 2012. http://dx.doi.org/10.1115/imece2012-86601.
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Gas dynamic cold spray was first discovered in the 1980s and has since been used as a surface coating process for depositing metals, metal-ceramic composites, metal-carbon nanotube composites and other composite materials onto both flexible and rigid substrates. We recently developed a focused cold spray material deposition tool termed Micro Cold Spray (MCS). MCS is a direct-write tool applicable for printed electronics and has been used to print conductive trace patterns as thin as 50 μm wide using copper, aluminum and tin micro powders. Unlike conventional aerosol processing at 10–100 m/s, aerosol particles in the MCS process are accelerated to speeds greater than 500 m/s. In this paper the possibility to accelerate, focus, collimate, and deposit aerosol particles is theoretically explored using a finite difference approximation method to simulate the flow of Helium through a symmetric converging-diverging nozzle of throat diameter 200 μm. A Lagrangian particle tracking algorithm is used to calculate the particle trajectories and corresponding velocities. This paper presents a comparison of the effect of Stoke’s drag force and Saffman’s lift force on the trajectory and velocity of copper particles 3 μm in diameter.
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Ortiz-Fernandez, R., and B. Jodoin. "Hybrid Additive Manufacturing Technology—Induction Heating Cold Spray." In ITSC2021, edited by F. Azarmi, X. Chen, J. Cizek, C. Cojocaru, B. Jodoin, H. Koivuluoto, Y. C. Lau, et al. ASM International, 2021. http://dx.doi.org/10.31399/asm.cp.itsc2021p0107.
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Abstract Cold Spray (CS) has gained special interest as a coating method due to the production of low oxide content deposits and solid-state deposition of powder material. This paper investigates the interaction between an electromagnetic field and cold-sprayed coatings produced using an induction heating cold spray (IHCS) system. It also investigates the role of the initial substrate surface temperature. The soft/hard material combination was used for depositing pure aluminum on Ti64 substrates. To assess the performance of the IHCS technique, deposition efficiency and adhesion and tensile strengths were used to characterize the hybrid technique. The results were compared to the traditional CS process. It was observed that the IHCS tensile samples exhibited almost three times the average elongation at break obtained by the traditional CS process. Intra-particle surface fracture was found in the samples produced by the hybrid process.
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Dabney, Tyler, Hwasung Yeom, Kyle Quillin, Nick Pocquette, and Kumar Sridharan. "Cold Spray Technology for Oxidation-Resistant Nuclear Fuel Cladding." In ITSC2021, edited by F. Azarmi, X. Chen, J. Cizek, C. Cojocaru, B. Jodoin, H. Koivuluoto, Y. C. Lau, et al. ASM International, 2021. http://dx.doi.org/10.31399/asm.cp.itsc2021p0167.
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Abstract Light water reactors (LWR) use zirconium-alloy fuel claddings; the tubes that hold the uranium-dioxide fuel pellets. Zr-alloys have very good neutron transparency; but during a loss of coolant accident or beyond design basis accident (BDBA) they can undergo excessive oxidation in reaction with the surrounding steam environment. Relatively thin oxidationresistant coatings on Zr-alloy fuel cladding tubes can potentially buy coping time in these off-normal scenarios. In this study; cold spraying; solid-state powder-based materials deposition technology has been developed for deposition of oxidation-resistant Cr coatings on Zr-alloy cladding tubes; and the ensuing microstructure and properties of the coatings have been investigated. The coatings when deposited under optimum conditions have very good hydrothermal corrosion resistance as well as oxidation resistance in air and steam environments at temperatures in excess of 1100 °C; while maintaining excellent adhesion to the substrate. These and other results of this study; including mechanical property evaluations; will be presented.
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Xie, Jing, Daniel Nelias, Hélène Walter-le Berre, Yuji Ichikawa, and Kazuhiro Ogawa. "Numerical Simulation of the Cold Spray Deposition Process for Aluminium and Copper." In ASME 2012 11th Biennial Conference on Engineering Systems Design and Analysis. American Society of Mechanical Engineers, 2012. http://dx.doi.org/10.1115/esda2012-82107.
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Cold spray is a rapidly developing coating technology for depositing materials in the solid state. In this deposition process, the spray particles are accelerated to a high velocity by a high-speed gas flow, and then form a dense and high quality coating due to plastic deformation of particles impinged upon the solid surface of substrate. 2D and 3D modelling of particle impacting behaviours in cold spray deposition process by using ABAQUS/Explicit was conducted for four couples of materials (i.e. impacting particle/impacted substrate): copper/aluminium, aluminium/copper, copper/copper, and aluminium/aluminium. A systematic analysis of a single impact was carried out considering different parameters, such as the initial impact velocity, initial temperature and contact angle, which affect the deposition process and subsequently the mechanical properties of coating. Three numerical methods have been evaluated and their performances are discussed for various simulation settings: (i) modelling in a Lagrangian reference frame; (ii) modelling using adaptive remeshing in an Arbitrary Lagrangian Eulerian (ALE) reference frame; and (iii), modelling in a CEL reference frame. It is found that the Coupled Eulerian Lagrangian (CEL) method has more advantages to simulate the large deformation of materials, and is also more efficient to prevent the excessive distortion of the mesh. A comparison between simulation results and experimental data from the literature was performed. Nevertheless, the CEL method is implicitly isothermal for ABAQUS v6.10, whereas the modelling in the classical Lagrangian reference frame does include coupled thermo-mechanical effects with a local increase of the temperature near the interface — due to friction — and for the highly plastically deformed elements — due to the heat dissipation linked to plasticity. A local rise of temperature at the impact surface may also be observed for oblique impacts. Finally a first attempt to simulate the deposition of several particles is made with a 3D CEL model, resulting in the creation of porosity at the interface between particles.