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Cold Spray Process Fundamentals
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Proceedings Papers
ITSC2023, Thermal Spray 2023: Proceedings from the International Thermal Spray Conference, 214-221, May 22–25, 2023,
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In high-pressure cold spray, the enthalpy of the particle carrier gas has a significant effect on the propellant gas conditions and ultimately on particle impact velocities and temperatures. Through modelling and experimentation, the current work demonstrates that in low-pressure cold spray, the particle carrier gas enthalpy has a minimal effect on the particle velocity and is rather limited to affecting the particle impact temperature. Consequently, particle impact temperature can be controlled independently from impact velocity. This is a valuable tool when dealing with temperature sensitive substrates: low propellant temperatures can be used in combination with high particle temperatures enabling particle deformation while minimizing substrate heat input. Particle preheating was used to inject pure aluminum particles in a commercial low-pressure cold spray to temperatures up to 500°C. This was accomplished without clogging because of the development of a novel particle preheater, which eliminated the particles exposure to hot metal surfaces. Even after substantial spray time, no evidence of wear or clogging was found. The particle preheating resulted in a deposition efficiency increase of 3.6 times when compared to the injection of room temperature particles.
Proceedings Papers
ITSC2023, Thermal Spray 2023: Proceedings from the International Thermal Spray Conference, 222-228, May 22–25, 2023,
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Metallization of polymers and fiber-reinforced polymer composites is gaining attention due to the widespread application of these components in various industries, such as wind energy, aerospace, and automotive industries. Cold spray is a promising new technique to achieve the metallization of polymer and fiber-reinforced polymer composites. This work investigates the deposition mechanisms of polymer-coated metallic particles on polymer-based substrates by finite element analyses. Impact mechanics of PEEK-coated nickel particles impacting PEEK and carbon fiber-reinforced PEEK substrates are modeled. Results show the prominence of mechanical interlocking of metallic particles in the substrate, which occurs due to their entrapment inside the substrate, caused by the high energy impact-induced welding of scraped PEEK coating. The PEEK coating acts as a cushioning component, effectively mitigating the impact energy of the metallic component. The scraped PEEK coating also accumulates on the upper half of the particle, forming a cap welded to the substrate and sealing the metallic particle inside. It is observed that the depth of the carbon fiber mat in the substrate affects the mechanism and the success of deposition.
Proceedings Papers
ITSC2023, Thermal Spray 2023: Proceedings from the International Thermal Spray Conference, 229-234, May 22–25, 2023,
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The clogging, a frequent gas passage deformation phenomenon because of powder accumulation on inner nozzle wall, is a major issue in long duration Cold Spray (CS) operations and a major challenge for Cold spray technology to be adopted for additive manufacturing. This study aims to design and integrate new nozzle design in Cold Spray operations for addressing the clogging issues in traditional circular convergent-divergent (CD) nozzles. The concept of the Aerospike nozzle is proposed for that purpose and is investigated using numerical simulation methods in this paper. An aerospike nozzle allows gases to accelerate externally bounded by environment on one-side and contoured spike wall on other side. After accelerating along the spike wall, aerospike nozzle can generate a longer supersonic gas stream. The spike region can be truncated near the tip to provide a flat face for powder injection. This proposed strategy will allow powder particles to accelerate through a longer supersonic core region, without interacting with nozzle wall. With appropriate operating parameters, an aerospike nozzle can reduce or eliminate the clogging issue completely. The efficiency and operation of aerospike nozzle is compared with same Mach number C-D nozzle using numerical simulations at stagnation pressure of 30 bar and temperature of 623K, where the aluminium powder particles are injected at 30 g/min in the centerline of both nozzles and are accelerated to similar velocities. The powder particles are accelerated in supersonic core region of aerospike nozzle without interacting with nozzle wall, it is concluded that the aerospike nozzle can be a promising nozzle design to provide clogging free long duration CS operations.
Proceedings Papers
ITSC2023, Thermal Spray 2023: Proceedings from the International Thermal Spray Conference, 235-241, May 22–25, 2023,
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The current work numerically evaluates the efficacy of a coflowing nozzle for cold spray applications with the aim to mitigate nozzle clogging by reducing the length of its divergent section. The high-pressure nitrogen flow through convergentdivergent axis-symmetric nozzles was simulated and the particle acceleration is modelled using a 2-way Lagrangian technique which is validated using experimental results. An annular co-flow nozzle with a circular central nozzle has been modelled for nitrogen gas. Reduction of nozzle divergent length from 189 mm to 99 mm showed an approximate 2.2% drop in particle velocity at high pressure operation while no variation at lower pressure operation was observed. Co-flow was introduced to the reduced nozzle length to compensate for particle velocity loss at higher operating conditions and it was found that co-flow facilitates momentum preservation for primary flow resulting in increased particle speed for a longer axial distance after the nozzle exit. The reduced divergent section nozzle, when combined with co-flow, is comparable to the original length nozzle.