scholarly journals Influence of Cold Spray Parameters on Bonding Mechanisms: A Review

Metals ◽  
2021 ◽  
Vol 11 (12) ◽  
pp. 2016
Author(s):  
Surinder Singh ◽  
R. K. Singh Raman ◽  
Christopher C. Berndt ◽  
Harpreet Singh
Keyword(s):  
Adhesion Strength ◽  
Cold Spray ◽  
Material Properties ◽  
Interfacial Properties ◽  
Spray Parameters ◽  
Cold Spray Process ◽  
Spray Process ◽  
Process Gas ◽  
Input Parameters ◽  
The Impact

The cold spray process is governed by the impact of high velocity feedstock particles onto a substrate without melting. Hence, the bulk material properties are retained. However, it is challenging to achieve good adhesion strength. The adhesion strength depends on factors such as the cold spray process parameters, substrate conditions, coating/substrate interactions at the interface and feedstock material properties. This review examines fundamental studies concerning the adhesion mechanisms of cold spray technology and considers the effect of cold spray input parameters such as temperature, stand-off-distance, pressure, process gas, spray angle, and traverse speed of the cold spray torch on the bonding mechanism and adhesion strength. Furthermore, the effects of substrate conditions such as temperature, hardness, roughness and material on the adhesion mechanism are highlighted. The effect of feedstock properties, such as feed rate, shape and size are summarized. Understanding the effect of these parameters is necessary to obtain the optimal input parameters that enable the best interfacial properties for a range of coating/substrate material combinations. It is expected that feedstock of spherical morphology and small particle size (<15 μm) provides optimal interfacial properties when deposited onto a mirror-finished substrate surface using high pressure cold spray. Deep insights into each parameter exposes the uncovered potential of cold spray as an additive manufacturing method.

Investigation on Residual Stress Development During Multiple Impacts in Cold Spray Process

2019 ◽  
Author(s):  
Sagil James ◽  
Karan Shah
Keyword(s):  
Cold Spray ◽  
Particle Deposition ◽  
Md Simulation ◽  
Substrate Surface ◽  
Spray Coating ◽  
Layer By Layer ◽  
Original Material ◽  
Cold Spray Process ◽  
Spray Process ◽  
The Impact

Abstract The Cold Spray Process (CS) is a solid-state particle deposition process. Unlike thermal spray coating methods, the CS process does not involve melting of the particles and thus retains the desired original material properties along with oxide-free deposition. As the technology is of dynamic nature with high-velocity particle impacts, the bonding mechanism involved is hugely complicated to understand. Even though the CS process offers great benefits, its potential applications are restrained by a lack of knowledge of the complex operations involved. Preliminary research which used molecular dynamics (MD) simulation of the CS process revealed that factors including the angle of impact, size of particle and impact velocity significantly affect the material deposition. However, the preliminary study only considered a single particle impact during the coating process. The CS process involves the impact of multiple particles on the substrate surface depositing layer-by-layer. This research focuses on investigating the residual stresses distribution caused by the impact of multiple nanoparticles on the substrate surface during the CS process using MD simulation technique. The results obtained by this study are instrumental in further advancing the applications of the CS processes.

On Simulation of Multi-Particle Impact Interactions in the Cold Spray Process

2012 ◽  
Author(s):  
Baran Yıldırım ◽  
Andrew Hulton ◽  
Seyed Ali Alavian ◽  
Teiichi Ando ◽  
Andrew Gouldstone ◽  
...  
Keyword(s):  
Cold Spray ◽  
Failure Criteria ◽  
Material Behavior ◽  
Impact Behavior ◽  
Strength Parameter ◽  
Cold Spray Process ◽  
Spray Process ◽  
Method Effects ◽  
Cohesion Degree ◽  
The Impact

The cold spray process consists of coating build-up by sequential impact, deformation and bonding of many particles. Therefore, formation and properties of a deposited layer are not only affected by the impact behavior of a single particle, but also by subsequent impact events. To investigate the material behavior under such conditions, impact of multiple particles in cold spray was studied here by the finite element method. Effects of high strain rates and temperature on material yield and failure criteria were considered. Particle conditions prior to impact were derived from fluid dynamics calculations. To predict sticking behavior of the particle, an interfacial cohesive strength parameter was defined between the particle and the substrate. The effects of temperature and particle positioning were examined for three particle impacts. In addition, simulations involving 100 consecutive particle impacts were carried out, and findings were compared with experimental observations. Results showed that subsequent impacts have a large effect on the previously impacted particles for cohesion, degree of deformation, and residual stresses.

Taguchi Based Optimization for Micro Hardness of Cold Spray Coating Process

2014 ◽  
Vol 2 (2) ◽  
pp. 23-33 ◽  
Author(s):  
Tarun Goyal ◽  
T.S. Sidhu ◽  
R.S. Walia
Keyword(s):  
Cold Spray ◽  
Low Pressure ◽  
Substrate Material ◽  
Stagnation Pressure ◽  
Stagnation Temperature ◽  
Micro Hardness ◽  
Cold Spray Process ◽  
Carrier Gas ◽  
Spray Process ◽  
Input Parameters

In this paper, low pressure cold spray process has been employed to produce coatings on three different substrates. The experiments have been designed using Taguchi L 18 array where the input parameters have been selected as the type of feed arrangement, substrate material, stagnation temperature, stagnation pressure of the compressed gas and stand-off distance. The effect of these key parameters on raw data and Signal to Noise (S/N) ratio for micro hardness of low pressure cold spray process has been studied. The coatings were successfully developed on the substrates and the micro hardness of the so produced coatings has been measured. The results show that a high value of micro hardness can be obtained by selecting the input parameters which increases the impact velocity of the striking particles. These high velocity impacting particles produces a peening effect to already attached powder particles thereby increasing the micro hardness of obtained coatings. It is seen that the significant process parameters are type of powder feeding arrangement, substrate material, stand-off distance stagnation pressure of carrier gas and stagnation temperature of the carrier gas.

scholarly journals SPH modeling of adhesion in fast dynamics: Application to the Cold Spray process

2016 ◽  
Vol 344 (4-5) ◽  
pp. 211-224 ◽  
Author(s):  
Paul Profizi ◽  
Alain Combescure ◽  
Kahuziro Ogawa
Keyword(s):  
Cold Spray ◽  
Cold Spray Process ◽  
Spray Process

Significant influence of carrier gas temperature during the cold spray process

2014 ◽  
Vol 30 (6) ◽  
pp. 443-450 ◽  
Author(s):  
S. Yin ◽  
X. Suo ◽  
H. Liao ◽  
Z. Guo ◽  
X. Wang
Keyword(s):  
Cold Spray ◽  
Significant Influence ◽  
Gas Temperature ◽  
Cold Spray Process ◽  
Carrier Gas ◽  
Spray Process

scholarly journals Deposition of Copper Fine Particle by Cold Spray Process

2009 ◽  
Vol 50 (6) ◽  
pp. 1482-1488 ◽  
Author(s):  
Masahiro Fukumoto ◽  
Hiroki Terada ◽  
Masahiro Mashiko ◽  
Kazunori Sato ◽  
Motohiro Yamada ◽  
...  
Keyword(s):  
Cold Spray ◽  
Fine Particle ◽  
Cold Spray Process ◽  
Spray Process

Multi-walled carbon nanotube-reinforced copper nanocomposite coating fabricated by low-pressure cold spray process

2012 ◽  
Vol 206 (16) ◽  
pp. 3488-3494 ◽  
Author(s):  
Seungchan Cho ◽  
Kenta Takagi ◽  
Hansang Kwon ◽  
Dowon Seo ◽  
Kazuhiro Ogawa ◽  
...  
Keyword(s):  
Carbon Nanotube ◽  
Cold Spray ◽  
Low Pressure ◽  
Nanocomposite Coating ◽  
Cold Spray Process ◽  
Spray Process ◽  
Multi Walled Carbon Nanotube

scholarly journals Microstructure, Mechanical Properties and Corrosion Behavior of the Aluminum Alloy Components Repaired by Cold Spray with Al-Based Powders

Metals ◽  
2021 ◽  
Vol 11 (10) ◽  
pp. 1633
Author(s):  
Zhiyi Zhang ◽  
Xiaoguang Sun ◽  
Shiming Huang ◽  
Xiaohui Han ◽  
Ping Zhu ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Aluminum Alloy ◽  
Cold Spray ◽  
Corrosion Behavior ◽  
High Speed ◽  
Neutral Salt ◽  
Cold Spray Process ◽  
Spray Process ◽  
High Speed Trains ◽  
Mechanical Properties And Corrosion

Aluminum alloy components of high-speed trains have a great risk of being corroded by various corrosive medium due to extremely complex atmospheric environments. This will bring out huge losses and reduce the safety and stability of trains. In order to solve the problem, cold spray process was used for repairing the damage of the aluminum alloy components with Al-based powders. Microstructure, mechanical properties and corrosion behavior were studied. The results indicated that there were very few pores and cracks in the repaired areas after repairing. The average microhardness of the repaired areas was 54.5 HV ± 3.4 HV, and the tensile strength of the repaired samples was 160.4 MPa. After neutral salt spray tests for 1000 h, the rate of mass loss of the samples repaired by cold spray was lower than that of 6A01 aluminum alloy. The electrochemical test results showed that the repaired areas had a higher open circuit potential than 6A01 aluminum alloy. As a result, the repaired areas such as the anode protected its nearby substrate. The samples repaired by cold spray exhibited better corrosion than 6A01 aluminum alloy. Cold spray process and Al-based powders are applicable for repairing the aluminum alloy components of high-speed trains.

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