A Review of the Mechanical and Tribological Behavior of Cold Spray Metal Matrix Composites

3D Microstructure-Based Finite Element Simulation of Cold-Sprayed Al-Al2O3 Composite Coatings Under Quasi-Static Compression and Indentation Loading

“…This is likely due to cold working, which introduces a hardening and strengthening effect in the matrix during the cold spray process. This is a result of the high-velocity hard ceramic particles impacting on the Al grains (Ref 18 , 63 ), which is not yet considered in the model. In addition to cold working, there are also other mechanisms that are likely to cause the deviations observed between the predicted and experimental stress versus strain histories as it relates to strain hardening behavior and elongation at failure.…”

“…Finally, the deviations between the simulation and experimental results can stem from the differences between the assumed and real boundary conditions (Ref 86 ), the complexities of the real microstructures such as reinforcing particle clustering (Ref 79 ) that are not yet incorporated into the generated RVEs, the fracture of reinforcing particles during the cold spray deposition process (Ref 18 ) leading to damage accumulation, and the increase in porosity due to interface decohesion and particle cracking (Ref 87 ), which are not considered in the GTN model implemented in the present study. In addition, the work hardening effect (Ref 88 ) induced in the Al matrix by the high-velocity impact of hard ceramic particles gives rise to a significant increase in dislocation density (Ref 89 ), which results in higher strength and hardness in the experimental samples when compared to the model material systems.…”

“…Among many deposition routes for producing coatings made of pure Al, cold spray stands out due to minimal heat loading of the substrate during the deposition process (Ref 17 ). In addition, this additive manufacturing method provides the possibility of producing multi-phase coatings via mixing feedstock powders by which the hard phases such as SiC and Al 2 O 3 can be incorporated effectively in the Al-MMCs coatings (Ref 18 ). These hard particles play a critical role in lowering the wear rate of the ceramic–metal coatings (Ref 19 ).…”

3D Microstructure-Based FE Simulation of Cold-Sprayed Al-Al2O3 Composite Coatings under Indentation and Quasi-Static Compression

“…This is likely to be caused by cold working, which introduces a hardening and strengthening effect in the matrix during the cold-spray process. This is as a result of the high-velocity hard ceramic particles impacting on the Al grains [18], which is not yet considered in the model. Figure 4 illustrates the contour of the plastic deformation [51], interfacial failure [26], and particle cracking [24] at two different axial strains during the loading process for the Al-34 wt.% Al2O3 composite.…”

“…Among many deposition routes for producing coatings made of pure Al, cold spray stands out due to minimal heat loading of the substrate during the deposition process [17]. In addition, this additive manufacturing method provides the possibility of producing multi-phase coatings through ad-mixing feedstock powders by which the hard phases such as SiC and Al2O3 can be incorporated effectively in the Al-MMCs coatings [18]. These hard particles play a critical role in lowering the wear rate of the ceramic-metal coatings [19].…”