This content is not included in
your SAE MOBILUS subscription, or you are not logged in.
Cold Spray Repair Process Optimization Through Development of Particle Impact Velocity Prediction Methodology
Technical Paper
2022-28-0098
ISSN: 0148-7191, e-ISSN: 2688-3627
Annotation ability available
Sector:
Language:
English
Abstract
Cold spray (CS) is a rapidly developing solid-state repair and coating process, wherein metal deposition is produced without significant heating or melting of metal powder. Solid state bonding of powder particles is produced by impact of high-velocity powder particles on a substrate. In CS process, metal powder particles typically of Aluminum or Copper are suspended in light weight carrier gas medium. Here high pressure and high temperature carrier gas is expanded through a converging-diverging nozzle to generate supersonic gas velocity at nozzle exit.
The CS process typically uses Helium as the carrier gas due to its low molecular weight, but Helium gas is quite expensive. This warrants a need to explore alternate carrier gases to make the CS repair process more economical. Researchers are exploring another viable option of using pure Nitrogen as a carrier gas due to its significant cost benefits over Helium. However, it shows challenges in achieving desired powder particle velocities and hence metal deposition efficiency. The work presented in this paper explores a carrier gas mixture of H2 and N2 as an alternate to Helium, to reduce the carrier gas cost.
This paper describes a CFD methodology developed for predicting particle impact velocities in CS repair process at the exit of converging diverging nozzle. The key challenge in developing CFD methodology was about coupling gas & powder particle flow dynamics and application of appropriate drag laws. This modeling methodology was able to predict particle velocity at nozzle exit with more than 95% accuracy. Subsequently CFD methodology was deployed to recommend suitable process parameters such as carrier gas composition, pressure, and temperature. The process parameters have been studied using a design of experiments (DoE) study with the aim of arriving at a carrier gas composition that can help in achieving critical deposition velocity at a reduced cost.
Authors
Topic
Citation
Bhardwaj, D., Bhise, O., Salutagi, S., and Roberts, K., "Cold Spray Repair Process Optimization Through Development of Particle Impact Velocity Prediction Methodology," SAE Technical Paper 2022-28-0098, 2022, https://doi.org/10.4271/2022-28-0098.Also In
References
- Alkhimov , A.P. , Kosarev , V.F. , and Papyrin , A.N. A Method of “Cold” Gas-Dynamic Spraying Doklady Akademii Nauk 315 5 1990 1062 1065
- Stoltenhoff , T. , Kreye , H. , Kroemmer , W. , and Richter , H.J. Cold Spraying—From Thermal Spraying to High Kinetic Energy Spraying Proceedings of the 5th HVOF Colloquium Erding, Germany 16 17 2000
- Grujicic , M. , Zhao , C.L. , DeRosset , W.S. , and Helfritch , D. Adiabatic Shear Instability Based Mechanism for Particles/Substrate Bonding in the Cold-Gas Dynamic-Spray Process Materials & Design 25 8 2004 681 688
- Dykhuizen , R.C. and Smith , M.F. Gas Dynamic Principles of Cold Spray Journal of Thermal Spray Technology 7 2 1998 205 212
- Samareh , B. , Stier , O. , Lüthen , V. , and Dolatabadi , A. Assessment of CFD Modeling via Flow Visualization in Cold Spray Process Journal of Thermal Spray Technology 18 5 2009 934 943
- Samareh , B. and Dolatabadi , A. A Three-Dimensional Analysis of the Cold Spray Process: The Effects of Substrate Location and Shape Journal of Thermal Spray Technology 16 5 2007 634 642
- Karimi , M. , Fartaj , A. , Rankin , G. , Vanderzwet , D. et al. Numerical Simulation of the Cold Gas Dynamic Spray Process Journal of Thermal Spray Technology 15 4 2006 518 523
- Dykhuizen , R.C. and Smith , M.F. Gas Dynamic Principles of Cold Spray Journal of Thermal Spray Technology 7 2 1998 205 212
- Wu , C.-Y. , Thornton , C. , and Li , L.-Y. Rebound Behaviour of Spheres during Elastic-Plastic Oblique Impacts International Journal of Modern Physics B 22 09n11 2008 1095 1102