Adiabatic shear instability based mechanism for particles/substrate bonding in the cold-gas dynamic-spray process

Grujičić, M.; Zhao, Changtai; DeRosset, W.S; Helfritch, D.J.

doi:10.1016/j.matdes.2004.03.008

Cited by 651 publications

(367 citation statements)

References 9 publications

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“…Based on these points, ASI may be considered as a prerequisite for bonding in CS of metallic materials [71]. Subsequent studies by various other researchers confirm the role of ASI in bonding.…”

Section: Window Of Deposition For Metallic Materialsmentioning

confidence: 90%

Cold spraying – A materials perspective

et al. 2016

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Cold spraying is a solid-state powder deposition process with several unique characteristics, allowing production of coatings or bulk components from a wide range of materials. The process has attracted much attention from academia and industry over the past two decades.The technical interest in cold spraying is twofold: first as a coating process for applications in surface technology, and second as a solid-state additive manufacturing process, offering an alternative to selective laser melting or electron beam melting methods. Moreover, cold spraying can be used to study materials behaviour under extremely high strain rates, high pressures and high cooling rates. The cold spraying process is thus considered to be relevant for various industrial applications, as well as for fundamental studies in materials science.This article aims to provide an overview of the cold spray process, the current understanding of the deposition mechanisms, and the related models and experiments, from a materials science perspective. IntroductionCold spraying (CS) is a solid-state material deposition technique, where micron-sized particles of a powder bond to a substrate as a result of high-velocity impact and the associated severe plastic deformation. Acceleration of particles to high velocities is obtained via expansion of a pressurised and (ironically) 'hot' gas through a diverging-converging nozzle.Despite heating the process gas -which is to provide higher acceleration of the gas and also to facilitate particle deformation through thermal softening -the feedstock remains in the solid state throughout the entire process; hence the name 'cold' spraying. This is to underline the contrast to conventional thermal spraying where particles are completely or partially molten upon impact onto the substrate. Alternative terminology includes cold gas spray, micro cold spray, cold gas dynamic spray, kinetic spray, supersonic particle deposition and metal powder application (MPA), all of which refer to the same principle of solid-state powder deposition as described above. CS is used for coating and repair. It is also used for additive manufacturing (AM) at relatively high deposition rates as compared to the methods based on selective laser or electron beam melting. The main advantage of CS is that it alleviates the problems associated with high temperature processing of materials, such as oxidation and unfavourable structural changes. It is possibly the only continuous method to produce bulk components of metastable materials that are available only in the powder form, e.g. as obtained from mechanical attrition or gas atomisation. The aim of the present paper is to provide an overview of CS from a materials perspective, particularly for a broader audience in materials research, e.g. with interest in dynamic phenomena, plasticity and phase transformations. In terms of application and properties, CS is perhaps best to be compared to thermal spraying processes, as in [24,25]. In view of relevant physical phenomena, however, CS is mos...

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Section: Window Of Deposition For Metallic Materialsmentioning

confidence: 90%

Cold spraying – A materials perspective

et al. 2016

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“…The contact interface temperature, strain, and other parameters [5][6][7][8] can be obtained by simulating the impact process. Currently, almost all numerical investigations in CS focus on crystalline materials.…”

Section: Introductionmentioning

confidence: 99%

Simulation of Deposition Behavior of Bulk Amorphous Particles in Cold Spraying

Zhou

Mou

et al. 2010

Mater. Trans.

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Bulk amorphous Zr 41:2 Ti 13:8 Cu 12:5 Ni 10 Be 22:5 powders were chosen as feedstock to investigate the deposition behavior of amorphous alloy particles in cold spraying. The constitutive equation of the particles was established. Using the finite element method, the effects of velocity and preheating temperature of the particles on their deformation behavior were studied, the temperature changes near the contact interface were calculated, the relationship between deposition behavior and effective bonding was analyzed, and finally the coating generation mechanism with the cooling conditions were discussed.

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“…These results indicate shear instability at the interface of the particle/substrate or particle/particle [42]. It is notable that during impact the deformation is highly concentrated in the narrow region around the interface of the particle and the substrate, resulting in the formation of a jet composed of highly deformed material [43]. The formation of this jet is showed in Figure 2.11 at different time periods.…”

Section: Particle Deformation and Bonding Mechanismmentioning

confidence: 89%

Influence of Alumina Addition to Aluminum Fins for Compact Heat Exchangers Produced by Cold Spray Additive Manufacturing

et al. 2015

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Aluminum and aluminum-alumina powder mixtures were used to produce pyramidal fin arrays on aluminum substrates using cold spray as an additive manufacturing process. Using aluminum-alumina mixtures instead of pure aluminum powder could be seen as a costeffective measure, preventing nozzle clogging. The fin geometries that were produced were observed using a 3D digital microscope to determine the flow passages width and fins geometric details. Heat transfer and pressure tests were carried out using different ranges of appropriate Reynolds numbers for the sought commercial application to compare each fin array and determine the effect of alumina content. It was found that the presence of alumina reduces the fins' performance when compared to pure aluminum but that they still outperform traditional fins. Numerical simulations were performed and were used to explain

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Adiabatic shear instability based mechanism for particles/substrate bonding in the cold-gas dynamic-spray process

Cited by 651 publications

References 9 publications

Cold spraying – A materials perspective

Cold spraying – A materials perspective

Simulation of Deposition Behavior of Bulk Amorphous Particles in Cold Spraying

Influence of Alumina Addition to Aluminum Fins for Compact Heat Exchangers Produced by Cold Spray Additive Manufacturing

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