Development of 3D Multicomponent Model for Cold Spray Process Using Nitrogen and Air

Abstract

Cold spray is a unique coating technology that allows for solid state deposition of particles under atmospheric pressure. In this paper, a three dimensional, Computational Fluid Dynamics (CFD) multicomponent model is developed to estimate cold spray gas conditions involving both nitrogen and air. Calibration of the model followed by validation is accomplished by considering the thermal history of substrate exposed to cold spray supersonic jet. The developed holistic multicomponent model is effective in determining the state of gas and particles from injection point to the substrate surface with the advantage of optimizing very rapid cold spray deposition in nanoseconds. The validation of k-ε type CFD multicomponent model is done by using the temperature measured for a titanium substrate exposed to cold spray nitrogen at 800 °C and 3 MPa. Heat transfer and radiation are considered for the de Laval nozzle used in cold spray experiments. The calibrated multicomponent model has successfully estimated the state of propellant gas for the chosen high pressure and high temperature cold spray conditions. Moreover, the multicomponent model predictions are in good agreement with a previous holistic three dimensional cold spray model in which only nitrogen was used as the surrounding as well as the propellant gas. OPEN ACCESSCoatings 2015, 5 689 Keywords: cold gas dynamic spraying; supersonic jet; computational fluid dynamics (CFD); coating technique; three dimensional multicomponent numerical model

Simultaneous Densification and Improvement of Cold Spray Additively Manufactured Ti-6Al-4V Properties via Electro Plastic Treatment

“…The Cold Spray Digital Twin (CSDT) inputs were similar to the industry scale Plasma Giken ® cold spray system of this study that included process temperature, pressure, feed rate, nozzle assembly and cooling system. The CSDT outputs were according to a validated 3D multicomponent CFD model, ANSYS™ CFX Solver® under Workbench™ version 2021R1 [47][48][49][50][51][52]. Details of numerical analysis, computational domain, boundary conditions, and particles tracking were published earlier [5,49,52], therefore a short explanation is provided here.…”

“…The CSDT outputs were according to a validated 3D multicomponent CFD model, ANSYS™ CFX Solver® under Workbench™ version 2021R1 [47][48][49][50][51][52]. Details of numerical analysis, computational domain, boundary conditions, and particles tracking were published earlier [5,49,52], therefore a short explanation is provided here.…”

An Overview of Cold Spray Additive Technology in Australia for Melt-less Manufacture of Titanium

“…A widely used two equation k-ε turbulence model, based on Reynolds-Average Navier-Stokes (RANS)-type transport equations for compressible fluid flow, was utilized for the numerical analysis. A commercially available computational fluid dynamics (CFD) package, ANSYS TM CFX Solver ® under Workbench TM v14.5.7 (ANSYS, Inc. Canonsburg, Pittsburgh, PA, USA) was employed with details explained elsewhere [11]. The CFD program was based on the finite volume method to solve the Navier-Stokes equations which were governed by the continuity equation, momentum equation and total energy equation [11].…”

“…A commercially available computational fluid dynamics (CFD) package, ANSYS TM CFX Solver ® under Workbench TM v14.5.7 (ANSYS, Inc. Canonsburg, Pittsburgh, PA, USA) was employed with details explained elsewhere [11]. The CFD program was based on the finite volume method to solve the Navier-Stokes equations which were governed by the continuity equation, momentum equation and total energy equation [11]. The 3D model was developed with consideration of other 1D and 2D numerical studies [7][8][9][10] to estimate velocity, temperature and location of impact for cold spray deposits.…”

“…The coupling of high speed propellant gas exiting the de Laval nozzle with the surrounding, stationary air provides more realistic predictions via 'multicomponent' simulation. The details of the developed 3D model can be found elsewhere [6,11]. In the present study, the model outcomes as a capability to compare the current industry scale cold spray systems performance is presented.…”