Gas Flow, Particle Acceleration and Heat Transfer in Cold Spray Additive Manufacturing

Purpose Application of cold spray technology may exhibit significant benefits for the additive manufacturing process, particularly for producing intricate objects. To ascertain the feasibility of such an application, this paper aims to present a numerical investigation of the effect of scaling down a convergent-divergent (de Laval) nozzle, which is typically used in the cold spray industry, on the compressible flow parameters and thermal characteristics. Design/methodology/approach The Navier–Stokes equations and energy equation governing compressible flow are numerically solved using a finite volume method with a coupled solver. The conjugate heat transfer technique is used to couple fluid and solid heat transfer domains and predict the local heat transfer coefficient between the solid and fluid. The use of various RANS turbulence models has also been investigated to quantify the effect of the turbulence model on the simulation. Findings The numerical results reveal that the flow and thermal characteristics are altered as the convergent-divergent nozzle is scaled down. The static pressure and temperature profiles at any section in the nozzle are shifted toward higher values, while the Mach number profile at any section in the nozzle is shifted toward a lower Mach number. The turbulent kinetic energy at the nozzle exit increases with the scaling down of the nozzle geometry. This study also provides convincing evidence that the adiabatic approach is still suitable even though the temperature of the nozzle wall is extremely high, as required for industrial application. Results indicate that it is feasible to use the available capabilities of the cold spray technology for additive manufacturing after scaling down the nozzle. Originality/value The idea of adopting cold spray technology for additive manufacturing is new and innovative. To develop this idea into a viable commercial product, a thorough understanding of the flow physics within a cold spray nozzle is required. The simulation results discussed in this paper demonstrate the effect that scaling down of a convergent-divergent nozzle has on the flow characteristics in the nozzle.

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EXPERIMENTAL STUDY OF THE EFFECT OF HYDRODYNAMIC UNSTEADINESS ON A TURBULENT TUBE GAS FLOW STRUCTURE AND HEAT TRANSFER

Proceeding of International Heat Transfer Conference 11 ◽

10.1615/ihtc11.2480 ◽

1998 ◽

Author(s):

Guenrikh A. Dreitser ◽

V. B. Bukharkin ◽

V. M. Kraev ◽

A. S. Neverov

Keyword(s):

Heat Transfer ◽

Experimental Study ◽

Flow Structure ◽

Gas Flow

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HEAT TRANSFER CHARACTERISTICS OF A GAS FLOW IN UNI-DIRECTIONAL POROUS COPPER PIPES

10.1615/ihtc16.pma.024153 ◽

2018 ◽

Cited By ~ 1

Author(s):

Y. Sato ◽

K. Yuki ◽

Y. Abe ◽

Risako Kibushi ◽

Noriyuki Unno ◽

...

Keyword(s):

Heat Transfer ◽

Gas Flow ◽

Heat Transfer Characteristics ◽

Transfer Characteristics ◽

Porous Copper

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RADIATION-CONVECTIVE HEAT TRANSFER BETWEEN GAS FLOW AND BLUNT BODIES OF POROUS INJECTION OF RADIATION ABSORBING SUBSTANCES

10.1615/ihtc4.3840 ◽

1970 ◽

Author(s):

V. P. Motulevich ◽

M.S. Bespalov ◽

A.N. Boyko ◽

V. M. Eroshenko ◽

E. D. Sergievskii ◽

...

Keyword(s):

Heat Transfer ◽

Convective Heat Transfer ◽

Convective Heat ◽

Gas Flow ◽

Blunt Bodies ◽

Porous Injection

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SHOCK WAVE INTERACTION NEAR A CYLINDER ALIGNED NORMAL TO A BLUNTED PLATE—PART I: GAS FLOW AND HEAT TRANSFER ON A PLATE NEAR A CYLINDER

TsAGI Science Journal ◽

10.1615/tsagiscij.2018026924 ◽

2018 ◽

Vol 49 (2) ◽

pp. 105-118

Author(s):

Volf Ya. Borovoy ◽

Vladimir Evguenyevich Mosharov ◽

Vladimir Nikolaevich Radchenko ◽

Arkadii Sergeyevich Skuratov

Keyword(s):

Heat Transfer ◽

Shock Wave ◽

Gas Flow ◽

Wave Interaction ◽

Shock Wave Interaction ◽

Flow And Heat Transfer

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Parameters Optimization of Auxiliary Gas Process for Double-Wire SS316L Stainless Steel Arc Additive Manufacturing

Metals ◽

10.3390/met11020190 ◽

2021 ◽

Vol 11 (2) ◽

pp. 190

Author(s):

Wei Wu ◽

Jiaxiang Xue ◽

Wei Xu ◽

Hongyan Lin ◽

Heqing Tang ◽

...

Keyword(s):

Stainless Steel ◽

Additive Manufacturing ◽

Process Parameters ◽

Evaluation System ◽

Gas Flow ◽

Interactive Effect ◽

Parameters Optimization ◽

Heat Accumulation ◽

Auxiliary Process ◽

Strength And Stiffness

Serious heat accumulation limits the further efficiency and application in additive manufacturing (AM). This study accordingly proposed a double-wire SS316L stainless steel arc AM with a two-direction auxiliary gas process to research the effect of three parameters, such as auxiliary gas nozzle angle, auxiliary gas flow rate and nozzle-to-substrate distance on depositions, then based on the Box–Behnken Design response surface, a regression equation between three parameters and the total score were established to optimized parameters by an evaluation system. The results showed that samples with nozzle angle of 30° had poor morphology but good properties, and increasing gas flow or decreasing distance would enhance the airflow strength and stiffness, then strongly stir the molten pool and resist the interference. Then a diverse combination of auxiliary process parameters had different influences on the morphology and properties, and an interactive effect on the comprehensive score. Ultimately the optimal auxiliary gas process parameters were 17.4°, 25 L/min and 10.44 mm, which not only bettered the morphology, but refined the grains and improved the properties due to the stirring and cooling effect of the auxiliary gas, which provides a feasible way for quality and efficiency improvements in arc additive manufacturing.

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