Experimental Verification of Statistically Optimized Parameters for Low-Pressure Cold Spray Coating of Titanium

Abstract

The cold spray coating process involves many process parameters which make the process very complex, and highly dependent and sensitive to small changes in these parameters. This results in a small operational window of the parameters. Consequently, mathematical optimization of the process parameters is key, not only to achieving deposition but also improving the coating quality. This study focuses on the mathematical identification and experimental justification of the optimum process parameters for cold spray coating of titanium alloy with silicon carbide (SiC). The continuity, momentum and the energy equations governing the flow through the low-pressure cold spray nozzle were solved by introducing a constitutive equation to close the system. This was used to calculate the critical velocity for the deposition of SiC. In order to determine the input temperature that yields the calculated velocity, the distribution of velocity, temperature, and pressure in the cold spray nozzle were analyzed, and the exit values were predicted using the meshing tool of Solidworks. Coatings fabricated using the optimized parameters and some non-optimized parameters are compared. The coating of the CFD-optimized parameters yielded lower porosity and higher hardness.

Sputtering Physical Vapour Deposition (PVD) Coatings: A Critical Review on Process Improvement and Market Trend Demands

“…FEM helps in studying the phenomenon related to the substrate and coating on their mechanical properties, such as strength, brittleness, adhesion, and performance, among others [31,32,[106][107][108]. CFD is typically focused on the study of fluid flow dynamics, anodic chamber performance prediction, thermal evaluation in a reactor's design, input temperature, the velocity of distribution of the species into the reactor, pressure, and others [109][110][111][112][113]. The quality of the coatings that were obtained in commercial PVD processes is of great importance and therefore its optimization.…”

Investigation of Tantalum Recycling by Electron Beam Melting

“…Therefore, theoretical investigation and application of different approaches-numerical, statistical, heuristic, etc. [4,18,[24][25][26][27][28][29][30][31][32][33][34][35][36][37][38]-are essential for the understanding and optimization of e-beam melting and refining technology. Consequently, modeling and mathematical optimization of the process parameters are important and key to improving the quality of the obtained pure metal, depending on the concrete characteristic requirements.…”

A Parametric Three-Dimensional Phase-Field Study of the Physical Vapor Deposition Process of Metal Thin Films Aiming at Quantitative Simulations

“…Moreover, the calculated R q to R a ratios for the thin films at the deposition rates of 0.22 and 1.0 nm s −1 agreed very well with the experimental data of the deposited Mo and Ti thin films. Finally, further discussion about the correlative behaviors between the surface roughness and the density was proposed for reasoning the shadowing effect as well as the formation of voids during the thin film production.Coatings 2019, 9, 607 2 of 15 properties [14][15][16][17]. However, in fact, PVD is a considerably sophisticated process and it is extremely difficult to improve the performance of the coating just through variation of the process parameters.…”

“…Coatings 2019, 9, 607 2 of 15 properties [14][15][16][17]. However, in fact, PVD is a considerably sophisticated process and it is extremely difficult to improve the performance of the coating just through variation of the process parameters.…”