Predicting the Effects of Powder Feeding Rates on Particle Impact Conditions and Cold Spray Deposited Coatings

Özdemir, Ozan Ç.; Widener, Christian; Carter, Michael J.; Johnson, Kyle W.

doi:10.1007/s11666-017-0611-0

Cited by 35 publications

(15 citation statements)

References 33 publications

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“…Of the commercially available alloy aluminum compositions in the powder marketplace, Al 6061 and Al 5056 also appear to have greater ease of deposition relative to Al 2024 and Al 7075. For example, by way of turning to Story's doctoral dissertation, the apparent inability of Al 7075 and Al 2024 to accommodate continued hardening due to the severe plastic deformation cold spray consolidation process shown in Figure 39 herein appears to correspond well with the only 80% deposition efficiency of Al 7075 and 60% deposition efficiency of Al 2024 reported upon in [132] when 100% of the carrier gas was comprised of He. On the other hand, Al 6061, which clearly maintained a greater capacity for work hardening as indicated by the jump in hardness due to cold spray as shown in Figure 39 reportedly maintained a deposition efficiency of 100% according to Ozdemir et al in [133].…”

Section: Direct Implications For Cold Spraymentioning

confidence: 70%

Nanomechanical Characterization for Cold Spray: From Feedstock to Consolidated Material Properties

Sousa

Gleason

Haddad

et al. 2020

Metals

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Cold gas-dynamic spray is a solid-state materials consolidation technology that has experienced successful adoption within the coatings, remanufacturing and repair sectors of the advanced manufacturing community. As of late, cold spray has also emerged as a high deposition rate metal additive manufacturing method for structural and nonstructural applications. As cold spray enjoys wider recognition and adoption, the demand for versatile, high-throughput and significant methods of particulate feedstock as well consolidated materials characterization has also become more notable. In order to address the interest for such an instrument, nanoindentation is presented herein as a viable means of achieving the desired mechanical characterization abilities. In this work, conventionally static nanoindentation testing using both Berkovich and spherical indenter tips, as well as nanoindentation using the continuous stiffness measurement mode of testing, will be applied to a range of powder-based feedstocks and cold sprayed materials.

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Section: Direct Implications For Cold Spraymentioning

confidence: 70%

Nanomechanical Characterization for Cold Spray: From Feedstock to Consolidated Material Properties

Sousa

Gleason

Haddad

et al. 2020

Metals

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“…Also, a higher feed rate results in a thicker and sharper profile of a single-track deposit. Powder feed rate between 10 and 30 g/s should be carefully selected for improved CS deposit quality [13,14]. 3.…”

Section: Processing Parameters In Cold Spraymentioning

confidence: 99%

“…The feed rate determines the nature of the gas-particle stream exiting the nozzle, and it has a direct influence on the particle impact velocity, . The higher the powder feed rate, the lower the particle velocity due to severe gas–particle interaction [ 13 ], akin to those described in Fig. 1 (c).…”

Section: Introduction and Overviewmentioning

confidence: 99%

Recent advances on bonding mechanism in cold spray process: A review of single-particle impact methods

Adaan-Nyiak

Tiamiyu

2022

Journal of Materials Research

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Cold spray (CS) processing is a layer-by-layer solid-state deposition process in which particles at a temperature below their melting point are launched to sufficiently high velocities to adhere to a substrate (and previously deposited particles), forming coatings/parts. Despite being in existence for over four decades, particle bonding mechanisms in the CS process are unclear due to the complex particle–particle/carrier gas interactions that obscure assessment. This review evaluates recent findings from single-particle impact approaches that circumvent these complexities and further provide new insights on bonding mechanisms. Theories on the evolution of oxide layer breakup and delamination, adiabatic shear instability, jetting, melting, and interface solid-state amorphization that contributes to bonding are assessed and carefully reviewed. Although there is a unified condition in which bonding sets on, this study shows that no singular theory explains bonding mechanism. Rather, dominant mechanism is a function of the prevailing barriers unique to each impact scenario. Graphical abstract

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“…The coating thickness and track profiles of the deposits are also affected by the rate of feeding of powders. Both thick and sharp track profiles can be generated by using higher feed rates [ 72 ].…”

Section: Cold Spray Process Parametersmentioning

confidence: 99%

The Study of Assessment Parameters and Performance Measurement of Cold Spray Technique: A Futuristic Approach Towards Additive Manufacturing

Kumar

Pandey

2022

MAPAN

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In recent years, high-performance additive manufacturing (AM) is being extensively investigated by the virtue of its unique benefits over traditional manufacturing processes. Complex components of Ti, Fe, Ni alloys can be manufactured with ease; however, other nonferrous alloys such as Al alloys, Mg alloys, and Cu alloys have the melting tendency during processing by laser, electron beam, or arc, hence not appropriate to be manufactured using additive manufacturing. The most useful and powerful tool recognized in AM in the last decade is the cold spray process. This paper puts forth a review of recent research innovations and the concept to build new materials in the field of AM technology. The author has highlighted the important properties including retention of original feedstock particles and oxide-free surface deposits during the entire coating process. The present research work focuses on the basic principle, bonding mechanism and impact phenomenon, and effect of nozzle parameters on mechanical properties of deposits associated with cold spray additive manufacturing. Furthermore, the concept to develop well-bonded coated deposits and its metallurgical behavior have also been studied. Various aspects of repair and maintenance against corrosion and wear along with strength and geometry restoration have also been highlighted in this paper.

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Predicting the Effects of Powder Feeding Rates on Particle Impact Conditions and Cold Spray Deposited Coatings

Cited by 35 publications

References 33 publications

Nanomechanical Characterization for Cold Spray: From Feedstock to Consolidated Material Properties

Nanomechanical Characterization for Cold Spray: From Feedstock to Consolidated Material Properties

Recent advances on bonding mechanism in cold spray process: A review of single-particle impact methods

The Study of Assessment Parameters and Performance Measurement of Cold Spray Technique: A Futuristic Approach Towards Additive Manufacturing

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