Effect of Impact Angle on Ceramic Deposition Behavior in Composite Cold Spray: A Finite-Element Study

Impact Deposition Behavior of Al/B4C Cold-Sprayed Composite Coatings: Understanding the Role of Porosity on Particle Retention

“…In this study, a three-dimensional (3D) model of a B C particle impacting on an Al substrate is modeled in an Abaqus/Explicit framework to systematically study the cold spray impact deposition process of ceramic/metal composites with a pore. The B C particle is regarded as deformable with elastic-plastic behavior taken into account, and this is in contrast to the previous models where ceramic particles are assumed to be elastic using isotropic elastic models [ 43 , 46 , 59 , 60 ]. Table 1 summarizes the JHB constants for the B C particle, and these constants are extracted from the previous study by Johnson and Holmquist [ 61 ].…”

“…Through simulations, it has been shown that the increase in particle impact velocity increases the temperature and plastic deformation of the contact area, which has been shown to have an influence on particle retention and final coating strength [ 44 ]. For example, Chakrabarty et al [ 45 , 46 ] numerically studied deposition and retention of a single ceramic particle on a metallic substrate at different particle densities, velocities, and impact angles, and found that the oblique spray angle, higher density, and velocity of the depositing particles resulted in increasing the jetting region which strengthened the particle retention on the substrate. In another study, Elkin et al [ 43 ] numerically studied the role of the surface roughness on the retention of irregular-shaped particles by using the Johnson–Cook [ 39 ] model and CEL technique and found that irregular particle shapes resulted in less porosity and better retention when compared to spherical particles [ 47 ].…”

Factors Affecting Adhesion in Metal/Ceramic Interfaces Created by Cold Spray

“…Furthermore, measuring adhesion strength between two particles is not possible with current available testing techniques. One way to evaluate the performance of specific process independent variables is monitoring ceramic retention (i.e., deposition efficiency of the ceramic phase) in the coating (Ref 75). While the abovementioned factors are important to promote mechanical interlocking and ceramic retention, they do not fully characterize the bonding mechanism as they neglect chemical bonds which may be critical to adhesion as will be addressed in the following sections.…”

“…60,70,[75][76][77]. Mechanical interlocking is suggested to be of primary importance for ceramic retention in MMC coatings (Ref 60,70,[75][76][77].…”

“…60,70,[75][76][77]. Mechanical interlocking is suggested to be of primary importance for ceramic retention in MMC coatings (Ref 60,70,[75][76][77]. Therefore, ceramic retention is promoted by enhanced deformation and crater depth achieved, for instance, by increasing substrate surface roughness (Ref 70), using softer metals (Ref 70), using angular ceramic powders(Ref 76,77) or depositing the ceramic by oblique impact (Ref…”