Powder Consolidation Using Cold Spray

Process Modeling and Emerging Applications

verfasst von: Atieh Moridi

Verlag: Springer International Publishing

Buchreihe : SpringerBriefs in Applied Sciences and Technology

Enthalten in: Springer Professional "Wirtschaft+Technik" , Springer Professional "Technik"

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Über dieses Buch

This book first presents different approaches to modeling of the cold spray process with the aim of extending current understanding of its fundamental principles and then describes emerging applications of cold spray. In the coverage of modeling, careful attention is devoted to the assessment of critical and erosion velocities. In order to reveal the phenomenological characteristics of interface bonding, severe, localized plastic deformation and material jet formation are studied. Detailed consideration is also given to the effect of macroscopic defects such as interparticle boundaries and subsequent splat boundary cracking on the mechanical behavior of cold spray coatings. The discussion of applications focuses in particular on the repair of damaged parts and additive manufacturing in various disciplines from aerospace to biomedical engineering. Key aspects include a systematic study of defect shape and the ability of cold spray to fill the defect, examination of the fatigue behavior of coatings for structural applications, and a novel working window at subcritical conditions to obtain porous structures. This book is exceptional in scope, and its review of finite element modelling at different length scales sheds light on future design and process improvement in emerging applications such as structural repair, metal additive manufacturing and metal foam design.

Inhaltsverzeichnis

Frontmatter

Chapter 1. Introduction

Abstract

This chapter covers the basic principles of cold spray, different apparatuses, and various material systems that have been studied so far. The latter includes metals, ceramics, metal matrix composites, polymers, and nanostructured powders. At the end of the chapter, a critical discussion on the future of this technology is provided.

Atieh Moridi

Chapter 2. Experiments

Abstract

The experimental procedure is described in details in this chapter. Surface treatments, including cold spray coating and shot peening (conventional and severe) are explained. Different experimental techniques including microstructural observation, nano/micro-hardness measurement, X-ray diffraction measurement of residual stress, roughness measurement, rotating bending fatigue test, coating bond strength and cohesion strength tests and contact angle measurement are discussed.

Atieh Moridi

Chapter 3. Modeling Cold Spray

Abstract

Particle/substrate interaction during cold spray (CS) deposition and the resultant bonding are of great importance because they affect coating characteristics. Experimental studies and computational modeling have been performed to get a better understanding of the bonding mechanism during CS as well as its mechanical behavior under different loading conditions. This chapter focuses on modeling approaches and is composed of four sections. In the first three sections, different approaches to model the impact of a single particle and the criteria to relate it to the bonding in CS are discussed. Section 3.1 discusses adiabatic shear instability and the Lagrangian approach to study impact phenomena. Section 3.2 is about the hybrid Lagrangian-analytical approach and uses energy criteria to assess bonding in CS. Section 3.3 uses the Eulerian framework to study material jet formation to analyze bonding in CS. These approaches are devoted to the impact phenomenon of particles to the substrate. In Sect. 3.4, the first attempt to model a consolidated coating is proposed. The model is used to understand the effect of defects such as interparticle boundaries and subsequent splat boundary cracking on the mechanical behavior of CS coatings.

Atieh Moridi

Chapter 4. Applications

Abstract

In its current state, cold spray (CS) is increasingly used in a variety of industries for a number of applications, including the corrosion resistant repairs, surface restoration, manufacturing of sputtering targets, deposition of WC-Co for hard chrome replacement coatings, electrical and thermal conductive coatings, braze joint preparation and deposition of NiCrAlY bond coats for thermal barriers. As applications multiply, CS will continue to expand to other non-traditional applications such as photovoltaic, wind, medical and architectural applications, in particular because of the ability of CS to deposit materials without altering their properties. In this chapter the focus is on some emerging applications of CS. This includes repairing damaged parts in Sect. 4.1 and additive manufacturing in Sect. 4.2. Section 4.3 presents a new deposition window for CS at subcritical condition to obtain coatings with designed porosities. Porous coatings/cellular structures will open up a variety of new applications for CS including but not limited to: biomedical, mass transfer, shock/electromagnetic wave absorption, anti-friction coatings, etc.

Atieh Moridi

Titel: Powder Consolidation Using Cold Spray
verfasst von: Atieh Moridi
Verlag: Springer International Publishing
Electronic ISBN: 978-3-319-29962-4
Print ISBN: 978-3-319-29961-7
DOI: https://doi.org/10.1007/978-3-319-29962-4

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