Journal articles on the topic 'Supersonic spray deposition'
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Singh, Harvinder, and Rajdeep Singh. "A Review Study of Cold Spray Coating Process." Asian Review of Mechanical Engineering 8, no. 1 (May 5, 2019): 28–30. http://dx.doi.org/10.51983/arme-2019.8.1.2463.
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Cold Spray coatings is a material deposition technique from the broad family of thermal spray coatings with the difference of depositing spray particles at the temperature below melting point as it is a solid state process. The spray particles are impinged on the substrate with supersonic velocities. This paper imparts some light on application of this emerging technique with pros and cons. As this technique come up from last 20 years yet practical area is limited and confined to some research only. As this is a quite beneficial technique and help require from public/private sector to commercialize this technique and hope in coming years it comes up with a good growth in this area.
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Ren, Zhi Qiang, Xiao Ming Wang, Qi Wei Wang, Chao Ji Zhou, and Yao Zhang. "Study on Anti-Corrosion Property of Nickel-Based Coatings on Copper Surface in Supersonic Particles Deposition." Applied Mechanics and Materials 778 (July 2015): 164–67. http://dx.doi.org/10.4028/www.scientific.net/amm.778.164.
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In this study, the anti-corrosion properties of nickel-based coatings on the surface of copper alloy were investigated, and damages caused by corrosion on the copper surface were resolved. Researchers prepared nickel-based coatings by supersonic particles deposition, and tested the anti-corrosion properties of brass substrate and nickel-based coating by electrochemical technology and neutral salt spray. The results show that, the corrosion current of coating decreased 35 times than that of matrix. The successive and pyknotic oxide film on the surface of coating prevented reaction of corrosion further. When it reached 500 hours, the corrosion rate closed to 0. Nickel-based coatings prepared by supersonic particles deposition contribute to the increase of corrosion resistance significantly, which verifies that it is feasible to prepare outstanding corrosion resisting nickel-based coating by supersonic particles deposition.
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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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SONG, WOOJIN, KYUBONG JUNG, DOO-MAN CHUN, SUNG-HOON AHN, and CAROLINE SUNYONG LEE. "DEPOSITION OF Al2O3 POWDERS USING NANO-PARTICLE DEPOSITION SYSTEM." Surface Review and Letters 17, no. 02 (April 2010): 189–93. http://dx.doi.org/10.1142/s0218625x10013710.
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In this paper, alumina film was deposited using supersonic micronozzle in nano-particle deposition System (NPDS). Powder deposition at room temperature is important in the field of film deposition since high processing temperature can be a serious limitation for the deposition on flexible substrate. Previously, many studies have been reported on particle deposition, such as aerosol deposition method (ADM) or cold spray method. However, these deposition methods cannot be applied to various types of powders. Recently, NPDS using aluminum nozzle was designed to resolve these problems but it cannot deposit precise patterns less than 1 mm. In this study, alumina particles were deposited using Silicon-based micronozzle in NPDS. Three-dimensional silicon micronozzle was fabricated using semiconductor processing method, specifically deep reactive ion etching (DRIE) method. The silicon micronozzle fabricated by Bosch process is advantageous over the conventionally used nozzle, since the hardness of silicon is higher than that of aluminum and the lifetime can be increased. In this study, alumina nano-particles were accelerated to supersonic level at the neck of micronozzle and deposited on the substrate in a low vacuum condition. The film characteristics were evaluated using field-emission scanning electronic microscope (FE-SEM) and alpha step to measure its thickness of the deposited layer. The deposition result showed that alumina powders were successfully deposited using the fabricated micronozzle by means of NPDS.
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Caliari, F. R., F. S. Miranda, D. A. P. Reis, A. M. Essiptchouk, and G. P. Filho. "Supersonic Plasma Spray Deposition of CoNiCrAlY Coatings on Ti-6Al-4V Alloy." Journal of Thermal Spray Technology 26, no. 5 (May 19, 2017): 880–89. http://dx.doi.org/10.1007/s11666-017-0563-4.
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Gulizia, Stefan, A. Trentin, S. Vezzù, Silvano Rech, Peter King, Mahnaz Z. Jahedi, and Mario Guagliano. "Characterisation of Cold Spray Titanium Coatings." Materials Science Forum 654-656 (June 2010): 898–901. http://dx.doi.org/10.4028/www.scientific.net/msf.654-656.898.
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Cold spray is a solid state spray deposition process utilizing a supersonic De Laval nozzle to accelerate fine particles to high velocities. Particles plastically deform on impact to the substrate and to each other to create dense well adhered structures. In this study, the microstructure and mechanical properties of cold spray Titanium coatings deposited using nitrogen gas at different gas temperature and pressure were examined. In general, it was found that gas-atomised CP-titanium powder is capable of producing dense coating structures on aluminium alloy (Al6061) substrates. The micro-hardness, oxygen and nitrogen content of the coatings were found to be slightly higher than powder in the as-received condition. It was also found the coating residual stress was purely compressive when cold spray is conducted at high gas pressure and temperature.
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Peng, Daren, Caixian Tang, Neil Matthews, Rhys Jones, Sudip Kundu, R. K. Singh Raman, and Alankar Alankar. "Computing the Fatigue Life of Cold Spray Repairs to Simulated Corrosion Damage." Materials 14, no. 16 (August 9, 2021): 4451. http://dx.doi.org/10.3390/ma14164451.
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This paper summarises the findings of an investigation into the durability of cold spray repairs, also known as supersonic particle deposition or SPD repairs, to simulated corrosion damage in AA7075-T7351 aluminium alloy specimens. A feature of this paper is that it is the first to show how to perform the mandatory durability analysis of repaired corroded structures, where the corroded material is first removed by machining and then repaired using cold spray, in a fashion consistent with the requirements delineated in USAF Structures Bulletin EZ-19-01, MIL-STD-1530D, and the US Joint Services Structural Guidelines JSSG2006.
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Garmeh, Saeed, Mehdi Jadidi, and Ali Dolatabadi. "Cold Spray for Additive Manufacturing: Possibilities and Challenges." Key Engineering Materials 813 (July 2019): 423–28. http://dx.doi.org/10.4028/www.scientific.net/kem.813.423.
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Cold spray (CS) is a deposition technique to form a coating from the particles with temperature lower than their melting point. In this technique, particles are accelerated by a supersonic flow of a carrier gas such as air or nitrogen. Upon impact, particles undergo significant plastic deformation that bonds them to the substrate. Since the particles are not molten, this deposition method does not apply a lot of heat to the substrate and this makes CS the best candidate for temperature sensitive and oxygen sensitive materials. CS can be adapted to form 3D objects following layer-by-layer approach. This is called cold gas dynamic manufacturing (CGDM) or cold spray as additive manufacturing. Developing complex shapes by CGDM may result in formation of inclined surfaces, corners and sharp edges. Deposition in those regions is often accompanied with challenges that affect the accuracy and efficiency of the manufacturing. In this study, CGDM for two typical shapes such as cylinder and frustum on a flat substrate has been simulated to represent the additively manufactured parts. Particle trajectories and impact conditions i.e. velocity and size distributions have been compared. The results of numerical modelling provided useful information for understanding the limitations and challenges associated with CGDM that can help us to improve the quality and precision of particle deposition.
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Klarić, Štefanija, Zlatko Botak, Damien J. Hill, Matthew Harbidge, and Rebecca Murray. "Application of a Cold Spray Based 3D Printing Process in the Production of EDM Electrodes." Tehnički glasnik 14, no. 1 (March 20, 2020): 27–31. http://dx.doi.org/10.31803/tg-20190719094329.
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Cold spray process principles allow the production of near-net-shape metal parts with a fast layer deposition by using 3D printing techniques via supersonic 3D deposition (SP3D). This innovative additive manufacturing process allows an easy and quick production of copper and aluminium parts with future possibilities to expand materials and alloys. The speed and materials enable the application of this cold spray based 3D printing process for the production of tools. In this paper, Electrical Discharge Machining (EDM) electrodes were fabricated by using SP3D to investigate its application in tool production. Requirements for the materials of electrodes and some existing solutions for the production of EDM electrodes with additive manufacturing methods are described first. The fabrication and experimental results are then presented for 3D printed copper EDM electrodes that were tested by using St 37-2 (DIN 17100) steel as the workpiece.
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Harihara Sudhan, K., G. Krishna Prasad, Nikhil K. Kothurkar, and A. R. Srikrishnan. "Studies on supersonic cold spray deposition of microparticles using a bell-type nozzle." Surface and Coatings Technology 383 (February 2020): 125244. http://dx.doi.org/10.1016/j.surfcoat.2019.125244.
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Cao, Peng, Brian Gabbitas, Asma Salman, De Liang Zhang, and Z. H. Han. "Consolidation of TiAl Powder by Thermal Spray Processes." Advanced Materials Research 29-30 (November 2007): 159–62. http://dx.doi.org/10.4028/www.scientific.net/amr.29-30.159.
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Thermal spray deposition has been widely used as a coating process for applying thin protective layers to the need-to-protect materials, or substrates. Recent technological developments in thermal spray processing, particularly cold gas spraying (CGS) and supersonic plasma spraying (S-PS), have enabled some emerging applications for making structural components. This paper reports on the results of our recent attempts to obtain thick TiAl coatings using three coating techniques: atmospheric plasma spraying (APS), S-PS and CGS. We successfully achieved a 3 mm thick coating using both APS and S-PS techniques, but failed in cold spray. A significant phase change was observed of the powder particles experienced during both APS and S-PS processes. Nevertheless, a considerable quantity of titanium oxides was observed in the APS coating.
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Ion, Alberto, Pierre Sallot, Victor Badea, Patrice Duport, Camelia Popescu, and Alain Denoirjean. "The Dual Character of MAX Phase Nano-Layered Structure Highlighted by Supersonic Particles Deposition." Coatings 11, no. 9 (August 29, 2021): 1038. http://dx.doi.org/10.3390/coatings11091038.
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MAX phase compounds offer an attractive mixture of ceramic–metallic properties due to their covalent ionic–metallic nature. Since their discovery, a great interest was attributed to their synthesis and potential applications, but the processing of pure compounds as coatings for industrial large-scale application is still considered a challenge. To date, a limited number of papers have evaluated the build-up of MAX phase coating by cold spray (CS), a novel cost-effective and productive spray technology used in both areas of research and industry. Employing CS, the hot gas-propelled material particles have ballistic impingement on a substrate where they undergo plastic deformation. Because of the brittleness, internal delamination, and limited deformability, the deposition of the pure MAX phase is rather challenging. This paper presents the building-up ability of dense MAX-phase coatings by CS with retained structures and compositions, in close relation with the substrate characteristics and phase composition that influences the dual character ceramic–metallic behaviour. Besides recent literature, the originality of this research consists of pioneering deposition of Ti3AlC2 that emphasizes the ceramic–metallic character influenced by the particle speed and the mechanical properties of both substrate and compound.
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Garmeh, Saeed, and Mehdi Jadidi. "Numerical Study on Particle Behavior and Deposition Accuracy in Cold Spray Additive Manufacturing." Coatings 12, no. 10 (October 14, 2022): 1546. http://dx.doi.org/10.3390/coatings12101546.
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Cold Spray additive manufacturing (CSAM) is an emerging technique to fabricate freestanding objects by depositing solid-state layers of materials. Thanks to its remarkable deposition rate and maneuverability, it can be tailored to manufacturing intricate geometries in aerospace industries. In comparison to other additive manufacturing techniques, it is the processing speed, solid-state deposition, and the cost that make CSAM unique. In this study, CSAM process was modeled for a system comprised of a high-pressure cold spray gun with axial powder injection. To represent the flow structure around the already built objects and the deposited layers of CSAM, three walls with different profiles are placed on a flat substrate. In this work, the gas-particle behaviors are studied at the vicinity of these non-axisymmetric objects that can be generalized to more complex geometries and the applications of CSAM. The model is 3D and aluminum and copper powders were used for the feedstock. The particles’ conditions upon impact, such as particles’ footprint and normal impact velocities are studied. The numerical results show that the deviation of particles which is caused by the supersonic flow inside the nozzle and the shock waves outside the nozzle defines the accuracy of the deposition. Furthermore, the results manifest the particle’s material and size have a significant influence on the acquired velocities and trajectories of the particles, and consequently on the resolution of the process. It is found that the profile of the deposited layers has some effects on the gas flow near the substrate which plays a role in the dispersion of fine particles.
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S, Kumar, Naveen M Chavan, and Srinivasa Rao D. "Cold spraying: A low temperature variant of thermal spray techniques to deposit metallic materials." Frontiers in Advanced Materials Research 1, no. 1 (May 30, 2019): 25–27. http://dx.doi.org/10.34256/famr1914.
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Cold spraying is a novel material deposition process in which micron size particles are accelerated to supersonic velocity on to a metallic substrate to obtain thick and dense coatings. Unlike other thermal spray coatings, the bonding mechanism is completely different. In conventional thermal spray techniques, melting and solidification upon impact dominates the bonding mechanism. In cold spraying, Plastic deformation induced adiabatic shear instability governs the bonding process in which adiabatic temperature rise, plastic strain at interface and flow stress collapse play a crucial role. Variety of material including pure metals, alloys, composites and cermets have been deposited using cold spraying for variety of applications. In this article, a brief introduction about the bonding mechanism and potential applications of cold spraying is being discussed.
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Ashokkumar, Mohankumar, Duraisamy Thirumalaikumarasamy, Tushar Sonar, Sampathkumar Deepak, Packkirisamy Vignesh, and Mani Anbarasu. "An overview of cold spray coating in additive manufacturing, component repairing and other engineering applications." Journal of the Mechanical Behavior of Materials 31, no. 1 (January 1, 2022): 514–34. http://dx.doi.org/10.1515/jmbm-2022-0056.
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Abstract Cold spray process (CSP) is a thermal spray technology in which coating (10–40 µm) is formed in the solid state by the impingement of power particles with supersonic velocity (200–1,200 m/s2) on coupon employing compressed gas jet, below the melting point of coating powder. It is commonly referred as cold gas dynamic spray, high velocity powder deposition, kinetic spray and kinetic energy metallisation process. Using CSP, various engineering materials (metals, polymers and ceramics) and its composites can be deposited. It is unique and promising approach for obtaining surface coating and offers various technological benefits over thermal spray as kinetic energy is employed for deposition rather than thermal energy. This offers great benefits in additive manufacturing (AM) to develop a component denser, low oxide coating free of tensile residual stresses, and undesired chemical reactions compared to conventional AM and coating techniques. Cold spray additive manufacturing (CSAM) is the powerful and emerging technique in the field of AM to develop engineering components with improved performance covering broad range of functionalities of surface, subsurface and interfaces. There are few flaws in this technique; however, extensive research work is going in CSAM and repairing of components to meet the real-time applications. The main objective of this review article is to summarise the history, effect of process parameters on surface coating, research and development in CSP along with its implementation in AM, component repairing and biomedical, antimicrobial and electrical applications. A discussion on future trends in CSAM is also provided at the end part of this article.
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Sripada, Jagannadh V. S. N., Megil F. Gallant, Gobinda C. Saha, Reeti Singh, and Jan Kondas. "Tantalum Based High-Pressure Cold Spray Coatings on Stainless Steel Substrate." Key Engineering Materials 813 (July 2019): 429–34. http://dx.doi.org/10.4028/www.scientific.net/kem.813.429.
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Tantalum as a transition element possesses good corrosion resistant properties, along with ductility and hardness. It is also one of the best heat-resistant material (melting point 2996°C) and is known for its high heat and electrical conductivity. In this research, Tantalum is deposited on stainless steel substrate using high-pressure cold spray (HPCS) method. Cold spray coating technology enables the deposition of powder feedstock without melting. Feedstock particles are propelled through a nozzle at supersonic velocities and they deform plastically on impact, resulting in good bonding strength to the substrate. The low temperature and solid-state deposition associated with cold spray allows refractory materials such as Ta, Mo, and W to be deposited without high temperature requirements. The objective of this work is to achieve a dense and nonporous coating microstructure with a high deposition efficiency. The hardness of as-received tantalum particles is found to be 279 HV0.3 and the microstructure is very dense. Tensile testing carried on the sample coated at a stagnation gas pressure of 50 bar and gas inlet temperature of 900°C exhibited an ultimate tensile strength of 442 MPa and adhesion strength of 77 MPa. Further mechanical properties of the coating in terms of hardness is carried out by nanoindentation. These results will be correlated with microstructural imaging and elemental analysis including morphology and composition using scanning electron microscopy and X-ray diffraction techniques.
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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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Zhu, Sheng, Yu Xiang Liu, Xiao Ming Wang, and Guo Feng Han. "Effect of Processing Parameters on Porosity and Bonding Strength in Supersonic Particles Deposition of Al-Si Alloy." Advanced Materials Research 721 (July 2013): 332–36. http://dx.doi.org/10.4028/www.scientific.net/amr.721.332.
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Effect of Supersonic Particles Deposition processing parameters on porosity and bonding strength of Al-Si coating on the surface of ZM5 Magnesium alloy was studied. The result shows that the porosity rates of Al-Si coating are all below 0.6% and the bonding strength is all above 35MPa. With air pressure increasing, the porosity of Al-Si coating reduces to below 0.3% and the bonding strength increases to above 40MPa. With spray distance increasing, the average percent voids of Al-Si coating tends to increase and the bonding strength is better between 160mm and 200mm. The minimum porosity and the maximal bonding strength of the coating can be reached when the speed of feeding powders is at 6r/s.
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Akin, Semih, Puyuan Wu, Jung-Ting Tsai, Chandra Nath, Jun Chen, and Martin Byung-Guk Jun. "A study on droplets dispersion and deposition characteristics under supersonic spray flow for nanomaterial coating applications." Surface and Coatings Technology 426 (November 2021): 127788. http://dx.doi.org/10.1016/j.surfcoat.2021.127788.
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Sharma, Mala M., Francis L. Wolff, Timothy J. Eden, and Victor K. Champagne. "Prediction of the Flattening Ratio and Hardness of Cold Sprayed Deposits." Solid State Phenomena 338 (October 28, 2022): 3–15. http://dx.doi.org/10.4028/p-3f4541.
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Cold spray technology is a solid-state deposition process where solid particles are accelerated to very high velocities by expanding a compressed gas through a supersonic nozzle. The particles impact a substrate located approximately 25 mm from the exit plane of the nozzle. Predicting the deformation and resultant properties helps in developing process parameters and tailoring coatings to get the desired properties. In this study, aluminum, copper, and nickel coatings were produced using a range of process parameters that produced different particle impact velocities. The Hollomon power law relationship and Johnson-Cook flow stress model were utilized to predict the hardness of cold spray coatings. Results showed there was good agreement between the predicted and measured hardness of the respective coatings. Additionally, a methodology was developed to measure deformation in the form of a flattening ratio of the deposited particles. There was good agreement between the predicted and measured flattening ratio, especially for the Al and Ni feedstock powders.
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Malama, Terence, Agripa Hamweendo, and Ionel Botef. "Molecular Dynamics Simulation of Ti and Ni Particles on Ti Substrate in the Cold Gas Dynamic Spray (CGDS) Process." Materials Science Forum 828-829 (August 2015): 453–60. http://dx.doi.org/10.4028/www.scientific.net/msf.828-829.453.
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This paper presents simulation of molecular dynamics for the deposition of Titanium (Ti) and Nickel (Ni) particles on Ti substrate during Cold Gas Dynamic Spray (CGDS) process. The influencing factors of the deposition process, such as particle incident velocity, particle size and particle temperature are taken into consideration. Ti and Ni were selected because of their potential applications in the aerospace, marine and bio-medical industries. CGDS is preferred because it is a state of the art technique by which coatings are created without significant heating of the sprayed powder. In CGDS, particles are accelerated to supersonic velocities using a high speed gas stream. However, there are inherent difficulties in relating particle deposition characteristics with influencing factors of the deposition process. Moreover, there is limited literature on molecular dynamics simulation of CGDS process. For this reason, this paper develops a simulation process for Ti and Ni particles under influence of many factors using molecular dynamics. In this process, particles are allowed to interact for a short time, giving a view of their motion. The trajectories of these particles are determined by numerically solving the Newton's equations of motion for a system of interacting particles, in which the forces between the particles are defined. The results of the simulation process show that higher incident velocities and larger particle sizes result in stronger interface between the particle and the substrate. Further, higher temperatures of the substrate and particles improve the bond strength.
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Liu, Qian Chu, Pud Baburamani, Wyman Zhuang, Darrem Gerrard, Bruce Hinton, Madabushi Janardhana, and Khan Sharp. "Surface Modification and Repair for Aircraft Life Enhancement and Structural Restoration." Materials Science Forum 654-656 (June 2010): 763–66. http://dx.doi.org/10.4028/www.scientific.net/msf.654-656.763.
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Maintenance of ageing military aircraft structures encompasses both engineering and scientific management. In support of this, surface modification and repair methods are used on an opportunity basis to extend the life of aircraft in terms of fatigue and safety. Often, certain surface modification technologies have proved to be both cost effective and amenable for safe application. Some candidate technologies include shot peening, cold spray, deep surface rolling, friction stir welding, laser shock peening, and laser cladding. Whilst some technologies have been successfully applied to Australian Defence Force (ADF) aircraft in the past, some newer technologies are also being considered. The supersonic particle deposition (SPD) technology also known as cold spray coating has been recently approved for application on a helicopter gear box. Another technology of significance to ADF application is Laser Cladding (LC) technology. This paper briefly summarises the research work on these technologies at DSTO and discusses potential applications for aircraft components in the near future. It also provides an analysis of technologies and their potential advantages and disadvantages.
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Dr. W.S. Abdul Wahab. "Coating Technology By Two – Phase (Cold gas – Solid particles) Flow." journal of the college of basic education 21, no. 87 (December 26, 2022): 157–69. http://dx.doi.org/10.35950/cbej.v21i87.8862.
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The surface coating process which is known as a cold spray (CS) of solid particles is performed by acceleration the solid particles for a certain metal to supersonic speeds through nozzle gas flow , are subsequently deposited by impact onto surface . Also this paper presents an analytical model for (CS) process , by assuming one dimensional isentropic flow , to demonstrate the dynamics of dilute two – phase (powder particles plus carrier gas) flow . Furthermore the equations for particle model are introduced , when heat transfers between the solid particles and assumed gas.
The velocity of the solid particles must be achieved to a critical value for carrying out an optimal deposition efficiency and a high coating quality , also several parameters , including gas condition such as stagnation pressure and temperature , the density of gas , in addition the particle characteristics and nozzle geometry affect on particle velocity then on the quality of coating .
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Lee, Jong-Gun, Bhavana N. Joshi, Jong-Hyuk Lee, Tae-Gun Kim, Do-Yeon Kim, Salem S. Al-Deyab, Il Won Seong, Mark T. Swihart, Woo Young Yoon, and Sam S. Yoon. "Stable High-Capacity Lithium Ion Battery Anodes Produced by Supersonic Spray Deposition of Hematite Nanoparticles and Self-Healing Reduced Graphene Oxide." Electrochimica Acta 228 (February 2017): 604–10. http://dx.doi.org/10.1016/j.electacta.2017.01.116.
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Li, Nan, Qiang Wang, Fang Dong, Xin Liu, Peng Han, and Yu Han. "Research Progress of Coating Preparation on Light Alloys in Aviation Field: A Review." Materials 15, no. 23 (November 30, 2022): 8535. http://dx.doi.org/10.3390/ma15238535.
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This paper systematically introduces the application status of coating-preparation technology on light alloys in the field of aviation parts repair. Included are the advantages and disadvantages of thermal spraying technology and laser cladding technology in the application process, as well as the research status and application prospects of the emerging cold spray (CS) technology and supersonic laser deposition (SLD) technology. Compared with traditional thermal-spraying technology, CS has many advantages, such as low spraying temperature, low oxygen content of the coating, and low porosity, which can effectively avoid oxidation, burning loss, phase change, and grain length during thermal spraying. CS can prepare oxygen-sensitive, heat-sensitive, amorphous, and nanomaterial coatings that are difficult to prepare by traditional thermal-spraying technology. However, in the preparation of high-strength super-hard alloys, CS has shortcomings such as low deposition efficiency and bonding strength. SLD overcomes the shortcomings of CS while inheriting the advantages of CS. In the future, both technologies will be widely used in repairing and remanufacturing in the field of aviation. Based on the principles of CS and SLD, this paper introduces, in detail, the deposition mechanism of the coating, and the specific application examples of CS in the aviation field at the present stage are described. The research and application status of the two technologies in the fields of anti-corrosion coating, wear-resistant coating, functional coating, repair, and remanufacturing in recent years are reviewed. Finally, the application and development prospects of CS and SLD are discussed.
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Шоринов, Александр Владимирович. "ПЕРСПЕКТИВЫ ПРИМЕНЕНИЯ ТЕХНОЛОГИИ ХОЛОДНОГО ГАЗОДИНАМИЧЕСКОГО НАПЫЛЕНИЯ ДЛЯ ЗАЩИТЫ И ВОССТАНОВЛЕНИЯ ДЕТАЛЕЙ ИЗ МАГНИЕВЫХ СПЛАВОВ." Aerospace technic and technology, no. 2 (April 26, 2018): 20–27. http://dx.doi.org/10.32620/aktt.2018.2.03.
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Magnesium alloys are widely used in modern technology, especially in the aviation and automotive industries, primarily due to low density, which allows reducing the weight of products and structures significantly. However, one of the main disadvantages of magnesium alloys is low corrosion resistance, which limits the possibilities of their wide application. A large number of magnesium parts of helicopters are prone to corrosion in places of contact with parts made of other metals forming a galvanic couple. Moreover, magnesium alloys are also susceptible to surface damage due to impact, which often occurs in the manufacture, repair and maintenance of aviation equipment. Scratches and damage can lead to local corrosion. It is shown that energy- and resource-saving cold spraying technology is effective and advanced technology for repairing and recovering of magnesium parts against corrosion. The cold gas-dynamic spraying technology is a relatively new industry among the processes of thermal spraying. The cold spray process is based on accelerating the metal powder particles with a supersonic gas stream in the Laval nozzle followed by an impact on the substrate and the formation of a coating. The process is characterized in that the powder material used in the spraying process does not melt and therefore the oxidation of the coating decreases; there are no phase changes in the material and no considerable heating of the substrate. The results of the analysis of the current state of cold spraying of protective and restorative coatings as well as the analysis of the aviation engines magnesium parts manufactured by «MOTOR SICH», their damages, in particular corrosion, causes of occurrence and current protection methods are accomplished. The works aimed to deposition of cold spray corrosion-resistant coatings and its application for restoration and protection of magnesium parts against corrosion are analyzed. The previous work in the field of cold spraying of anticorrosive coatings was mainly aimed to achieving maximum density of coatings, since the absence of through porosity provides reliable protection of the base material. Coatings with a minimum porosity were obtained using the high-pressure cold spray systems. The analysis showed that the issue of using low-pressure cold-spray equipment remains open and confirms the urgency of further research
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Шорінов, Олександр Володимирович, Андрій Олегович Волков, Сергій Євгенійович Маркович, and Анатолій Іванович Долматов. "РОЗРАХУНОК ТЕМПЕРАТУРНО-ШВИДКІСНИХ ПАРАМЕТРІВ ЧАСТИНОК ПРИ ХОЛОДНОМУ ГАЗОДИНАМІЧНОМУ НАПИЛЮВАННІ." Aerospace technic and technology, no. 7 (August 31, 2019): 139–44. http://dx.doi.org/10.32620/aktt.2019.7.20.
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The method of computational fluid dynamics (CFD) for the supersonic nozzle SK-20 of the low-pressure cold gas-dynamic spraying equipment DYMET-405 was applied for calculation of particles impact temperature and velocity. The application of the CFD method is the one-dimensional isentropic gas-dynamic model considers the flow only along the nozzle axis, without taking into account the heat exchange with the nozzle and the friction losses on the internal walls, which leads to obtaining overestimated results of calculations. Previously it was found out that the difference in the values obtained by numerical simulation and the results of calculations of a one-dimensional isentropic model was less than 10%. Numerical simulation of the two-phase flow of the cold spray process has been performed using the Ansys Fluent Academic software package. The influence of the initial cold spray process parameters such as temperature and pressure at the nozzle inlet on the change in temperature and velocity of aluminum particles with a diameter of 25 μm at the moment of impact with the substrate has been studied. Also, the influence of the particle size on the above-mentioned parameters has been obtained. The numerical simulation results of the particle impact temperature with the substrate have been used to calculate the critical velocity of aluminum powder – the velocity needed for coating formation. It is known that the formation of cold spray coatings depends on the velocity of the powder particles. For each material, there is a critical velocity at which the process of forming the coating begins. At particle velocities above the critical one, their adhesion to the substrate and the formation of the coating, due to the plastic deformation of the particles, occurs, while at lower velocities the surface erosion or deposition with low efficiency under certain conditions is observed. As a result of simulation and calculations of the critical velocity, the window of spraying was developed, that is the region of values of velocities and temperatures of the particles of aluminum powder, depending on the temperature and pressure of the air at the nozzle inlet, at which the formation of coatings is possible.
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Hu, Wenjie, Sergii Markovych, Kun Tan, Oleksandr Shorinov, and Tingting Cao. "SURFACE REPAIR OF AIRCRAFT TITANIUM ALLOY PARTS BY COLD SPRAYING TECHNOLOGY." Aerospace technic and technology, no. 3 (June 26, 2020): 30–42. http://dx.doi.org/10.32620/aktt.2020.3.04.
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Titanium alloys have the advantages of high specific strength, good corrosion resistance, high heat resistance, and low density, which is the main structural material of aerospace system components, including compressor blade, cartridge receiver, blisk, engine nacelle, thermal baffle and so on. At present, about three-quarters of titanium and titanium alloys in the world are used in the aerospace industry, including A350 for 14%, F18 for 15 %, B787 for 15 %, SU-57 for 18 %, J-20 for 20 %, FC-31 fighters for 25 %, F35 for about 27 %, and F22 up to 41 %, etc, so it has the reputation of "space metal". However, its low wear resistance limits the further development of titanium alloy. Besides, its high manufacturing cost, if only require the occasion of surface performance can reduce the use of the substrate, and then reduced the cost. Therefore, the study of aircraft titanium alloy is of great significance, the protection of titanium alloy includes alloying technology and coating technology. Alloying technology mainly adds other elements on its basis to improve the performance, while the most popular method is coating technology, the present, there are many coating technologies, include high-velocity oxy-fuel (HVOF), HVAF, cold spraying, laser cladding, laser micro-fusion in-situ synthesized technology, micro-arc oxidation, laser melt injection (LMI), supersonic laser deposition (SLD) and supersonic plasma spray technology, surface repair titanium alloy parts by cold spraying technology are good ways to solve those problems. Because of its low process temperature, no oxidation, only plastic deformation, and repair efficiency are high, the protective coating has high bonding strength and good impact toughness. In this paper, the types and applications of aircraft titanium alloys were reviewed, the latest research results of surface repair of titanium alloys parts by cold spraying technology were reviewed, technological parameters of the cold gas dynamic spraying technology was analyzed, including powder size of particles, morphologies, critical velocity, particle compression rate, substrate preheating effects on the particle/substrate adhesion, etc.
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von Niessen, Konstantin, and Malko Gindrat. "Vapor Phase Deposition Using a Plasma Spray Process." Journal of Engineering for Gas Turbines and Power 133, no. 6 (February 14, 2011). http://dx.doi.org/10.1115/1.4002469.
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Plasma spray-physical vapor deposition (PS-PVD) is a low pressure plasma spray technology recently developed by Sulzer Metco AG (Switzerland) to deposit coatings out of the vapor phase. PS-PVD is developed on the basis of the well established low pressure plasma spraying technology. In comparison to conventional vacuum plasma spraying and low pressure plasma spraying, these new processes use a high energy plasma gun operated at a work pressure below 2 mbar. This leads to unconventional plasma jet characteristics, which can be used to obtain specific and unique coatings. An important new feature of PS-PVD is the possibility to deposit a coating not only by melting the feed stock material, which builds up a layer from liquid splats, but also by vaporizing the injected material. Therefore, the PS-PVD process fills the gap between the conventional PVD technologies and standard thermal spray processes. The possibility to vaporize feedstock material and to produce layers out of the vapor phase results in new and unique coating microstructures. The properties of such coatings are superior to those of thermal spray and electron beam-physical vapor deposition (EB-PVD) coatings. In contrast to EB-PVD, PS-PVD incorporates the vaporized coating material into a supersonic plasma plume. Due to the forced gas stream of the plasma jet, complex shaped parts like multi-airfoil turbine vanes can be coated with columnar thermal barrier coatings using PS-PVD. Even shadowed areas and areas, which are not in the line-of-sight to the coating source, can be coated homogeneously. This paper reports on the progress made by Sulzer Metco to develop a thermal spray process to produce coatings out of the vapor phase. Columnar thermal barrier coatings made of yttria stabilized zircona are optimized to serve in a turbine engine. This includes coating properties like strain tolerance and erosion resistance but also the coverage of multiple air foils.
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Takana, Hidemasa, HongYang Li, Kazuhiro Ogawa, Tsunemoto Kuriyagawa, and Hideya Nishiyama. "Computational and Experimental Studies on Cavity Filling Process by Cold Gas Dynamic Spray." Journal of Fluids Engineering 132, no. 2 (February 1, 2010). http://dx.doi.org/10.1115/1.4000802.
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Time-dependent computational simulations on cavity filling process by cold gas dynamic spray and powder jet deposition process ranging from microscale to macroscale were carried out in order to give an insight for their advanced applications to joining, crack repair, and dental treatment. Shock wave appears in front of the substrate due to underexpansion of jet and in-flight particles interact with the shock wave before their impact. The relation between shock wave, cavity configuration, and particle in-flight behavior in supersonic jet has been discussed in detail. Based on numerical and experimental studies, it was found that when the shock wave covers up the cylindrical cavity, the cavity cannot be filled at all by deposited powders. Moreover, under the condition of shock wave appearing inside the cylindrical cavity, conical deposition was formed due to the secondary back flow jet along the cavity side wall. By adopting conical cavity, cavity can be filled completely resulting from the suppression of the secondary back flow jet along the cavity side wall.
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Smith, M. F., J. E. Brockmann, R. C. Dykhuizen, D. L. Gilmore, R. A. Neiser, and T. J. Roemer. "Cold Spray Direct Fabrication – High Rate, Solid State, Material Consolidation." MRS Proceedings 542 (1998). http://dx.doi.org/10.1557/proc-542-65.
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AbstractDirect fabrication of metal near-net shapes from a computer model typically involves melting and solidification, which can cause high residual stresses, undesirable phases, poor microstructures, rough surface finishes, warpage, and other problems. This paper describes a new technology, still under development, that might be used to directly fabricate solid, near-fulldensity, free-form shapes of many metals, and even some composite materials, at or near room temperature without melting and solidification. In this process, tentatively called Cold Spray Direct Fabrication (CSDF), powder particles in a supersonic jet of compressed gas impact a solid surface with sufficient energy to cause plastic deformation and consolidation with the underlying material by a process thought to be analogous to explosive welding. Material deposition by cold spray methods has already been successfully demonstrated by several investigators. This paper presents results of an experimental study to investigate the effects of selected process variables on cold spray particle velocities. In addition, a key technical barrier to the CSDF concept is focusing the spray stream down to dimensions that would permit a useful level of part detail, while still providing practical build rates. This paper presents results of initial research to develop an aerodynamic lens that may provide the required particle stream focusing.
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Guo, D., M. Kazasidis, A. Hawkins, N. Fan, Z. Leclerc, D. MacDonald, A. Nastic, et al. "Cold Spray: Over 30 Years of Development Toward a Hot Future." Journal of Thermal Spray Technology, May 2, 2022. http://dx.doi.org/10.1007/s11666-022-01366-4.
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AbstractCold Spray (CS) is a deposition process, part of the thermal spray family. In this method, powder particles are accelerated at supersonic speed within a nozzle; impacts against a substrate material triggers a complex process, ultimately leading to consolidation and bonding. CS, in its modern form, has been around for approximately 30 years and has undergone through exciting and unprecedented developmental steps. In this article, we have summarized the key inventions and sub-inventions which pioneered the innovation aspect to the process that is known today, and the key breakthroughs related to the processing of materials CS is currently mastering. CS has not followed a liner path since its invention, but an evolution more similar to a hype cycle: high initial growth of expectations, followed by a decrease in interest and a renewed thrust pushed by a number of demonstrated industrial applications. The process interest is expected to continue (gently) to grow, alongside with further development of equipment and feedstock materials specific for CS processing. A number of current applications have been identified the areas that the process is likely to be the most disruptive in the medium-long term future have been laid down.
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Samareh, B., and A. Dolatabadi. "Dense Particulate Flow in a Cold Gas Dynamic Spray System." Journal of Fluids Engineering 130, no. 8 (July 30, 2008). http://dx.doi.org/10.1115/1.2957914.
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The effect of particle-gas and particle-particle interactions in a cold spray process is studied when the particle loading is high. To examine the effect of the presence of a dense particulate flow on the supersonic gas, an Eulerian-Eulerian approach is used. It is found that when the volume fraction of the injected particles is increased, the turbulence of the gas phase will be augmented by the motion of particles and consequently, the shape, the strength, and the location of the compression and expansion waves will be altered. Shock-particle interactions are demonstrated for various volume fractions. Another important parameter, which will affect the spraying deposition efficiency, is the substrate stand-off distance. It is found that the stagnation pressure alternates for different stand-off distances because of the formation of compression and expansion waves outside the nozzle exit. The particle normal velocity on impact is a strong function of the stagnation pressure on the substrate as particles must pierce through the bow shock formed on that region. The effect of the particle size and number density are also studied for different loading conditions. It is found that small and large particles behave differently as they pass through shock diamonds and the bow shock, i.e., in the case of very small particles, as the loading increases, the impact velocity increases, while, for the large particles, the trend is reversed.
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Morgan, R. H., C. J. Sutcliffe, J. Pattison, M. Murphy, C. Gallagher, A. Papworth, P. Fox, and W. O'Neill. "Cold Gas Dynamic Manufacturing – A new approach to Near-Net Shape Metal Component Fabrication." MRS Proceedings 758 (2002). http://dx.doi.org/10.1557/proc-758-ll2.6.
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ABSTRACTCold Gas Dynamic Manufacturing (CGDM) is a high-rate, direct deposition process capable of combining many dissimilar materials in the production of a single component. The process is based on Cold Gas Dynamic Spraying (CGDS) – a surface coating technology in which small, un-heated particles are accelerated to high velocities (typically above 500 m/s) in a supersonic gas jet and directed towards a substrate material. The process does not use a heat source (as with similar plasma and HVOF spray technologies), but rather employs the high kinetic energy of the particles to effect bonding through plastic deformation upon impact with the substrate or previously deposited layer. As a consequence it lends itself to the processing of temperature sensitive material systems such as oxidising, phase-sensitive or nano-structured materials. To achieve metallic bonding incident particles require velocities greater than a certain material-specific threshold value, such that thin surface films are ruptured, generating a direct interface. This bonding mechanism has been compared to explosive welding.This paper discusses the further development of the CGDS technique from surface coating technology into the basis for a novel Additive Fabrication process. The description of the apparatus is presented in addition to the basic processing conditions for the deposition of aluminium material. Particular attention is paid to the morphology of the deposited material, the microstructure and the interfacial boundary between splats.