General aspects of interface bonding in kinetic sprayed coatings

Bae, Gyuyeol; Xiong, Yao; Kumar, Santosh; Kang, Ki-Weon; Lee, Changhee

doi:10.1016/j.actamat.2008.06.003

Cited by 389 publications

(189 citation statements)

References 21 publications

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“…Several other studies have used FEM to investigate particle impact and deformation under various impact conditions and material combinations [45,[52][53][54][55][56][57][58]. Most of these studies are based on Lagrangian formulation implemented in commercial software.…”

Section: Numerical Simulationmentioning

confidence: 99%

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: Numerical Simulationmentioning

confidence: 99%

Cold spraying – A materials perspective

et al. 2016

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“…Many complex phenomena take place during deposition, including: work hardening, formation of adiabatic shear instabilities and recrystallization [21][22][23][24]. The plastic deformation and formation of the adiabatic shear instability are believed to contribute to the bonding [25][26][27][28] for both particle to substrate (i.e. coating adhesion) and particle to particle (i.e.…”

Section: Introductionmentioning

confidence: 99%

Mechanical behavior of Ti cold spray coatings determined by a multi-scale indentation method

Goldbaum

Ajaja

Chromik

et al. 2011

Materials Science and Engineering: A

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“…Additionally, according to results from particle impact modeling using ABAQUS conducted by many researchers, the inner region of the particles is not significantly heated relative to the vicinity of the interface between particle-particle and particle-substrate at the moment of impact, where the temperature increases to 0.99 T m (Ref [9][10][11][12][13]. Thus, in terms of the entire kinetic-sprayed deposit, virtually no phase transformation or chemical reaction (i.e., formation of intermetallic compounds) occurs during the deposition stage.…”

Section: As-sprayed Specimensmentioning

confidence: 99%

Microstructure of Kinetic Spray Coatings: A Review

2015

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Kinetic spray process has been applied to various industrial fields such as automotive, aviation, and defense industries due to its availability to produce high-performing coating layer. However, since the properties of kinetic-sprayed coating layer are significantly affected by the microstructures of deposit, the microstructures of the deposit should be controlled to acquire advanced coating layer and, accordingly, deep understanding of microstructural evolution must be achieved before controlling the microstructure of the coating layer. This paper gives an overview of contents related to the microstructure of kineticsprayed deposition. The most powerful influencing factors in microstructural evolution of kinetic-sprayed coating layer are instant generation of thermal energy and high-strain, high-strain-rate plastic deformation at the moment of particle impact. A high-density coating layer with low porosity can be produced, although some micro-cracks are occasionally induced at the interparticle boundary or at the inner region of the particles. Also, a microstructure which is distinct from the inner particle region is created in the vicinity of the particle-particle or particle-substrate interface region. However, almost no crystal phase transformation or chemical reaction is induced since the deposited particles are not heated directly by a thermal energy source.

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General aspects of interface bonding in kinetic sprayed coatings

Cited by 389 publications

References 21 publications

Cold spraying – A materials perspective

Cold spraying – A materials perspective

Mechanical behavior of Ti cold spray coatings determined by a multi-scale indentation method

Microstructure of Kinetic Spray Coatings: A Review

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