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S. Shinkai
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Proceedings Papers
ITSC 2008, Thermal Spray 2008: Proceedings from the International Thermal Spray Conference, 1228-1233, June 2–4, 2008,
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Nozzle geometry influences gas dynamics, such as gas density, velocity and temperature, making sprayed particle behavior one of the most important parameters in cold spray process. Gas flow at the entrance convergent section of the nozzle takes place at relatively high temperature and are subsonic. Thus, this region is a very suitable environment for heating spray particle. In this study, numerical simulation and experiments were conducted to investigate the effect of nozzle contour (convergent –divergent and convergent-divergent-barrel), entrance geometry of convergent–divergent nozzle and powder injection position at nozzle on the cold spray process. The process changes inside the nozzle were observed through numerical simulation studies and the results were used to find a correlation with coating properties. A copper and titanium powder was used in the experiments. Working gas (is nitrogen) pressure and temperature at nozzle-intake were 3MPa and 623K, respectively. In addition, the change in the nozzle contour and the change in the entrance convergent section length of the gun nozzle were found to have a slight effect on the coating microstructure. Powder injection position was also found to influence deposition efficiency and coating properties. Deposition efficiency of both copper and titanium increase with increasing the length of the convergent section of the nozzle.
Proceedings Papers
ITSC 2007, Thermal Spray 2007: Proceedings from the International Thermal Spray Conference, 13-18, May 14–16, 2007,
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Currently, graphite is used for anodes of the lithium ion battery. The higher capacity of a battery with the lithium alloy anode requires the development of a larger theoretical electrochemical capacity than graphite. Silicon is a promising anode material, having a theoretical capacity more than 10 times that of the graphite used in these lithium alloy batteries. There are two common methods of fabricating silicon anodes: direct deposition techniques such as electron beam deposition and sputtering; and slurry coating of silicon particles with a binder. Alternative methods are being investigated. One of such methods is cold spray. In this study, numerical simulation of, and experiments investigating, cold spray conditions and the performances of cold-sprayed silicon anodes are presented. Silicon was cold-sprayed on copper foil substrates using three different starting materials (with particle sizes of 4.65 µm, 6.74 µm and 9.63 µm). First cycle efficiency was about 90%. Charge capacity initially improves with cycling (up to the 10th cycle). This is probably due to better electrolyte soaking during the first several cycles. A decrease in charge capacity is observed upon further cycling.
Proceedings Papers
ITSC 2005, Thermal Spray 2005: Proceedings from the International Thermal Spray Conference, 164, May 2–4, 2005,
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Powder size, which influence on spray particle behavior in super sonic gas flow in and out of nozzle, is one of the most important parameters in cold spray process. In the other hands, it was reported that small particles (smaller than 5ƒÊm in diameter) decelerate significantly close to the substrate by the bow shock in cold spray. In this study, numerical simulation and experiments investigated the effect of the powder size of copper on the cold spray process and the structures and properties of the cold sprayed coatings. In the numerical simulation, it is assumed that gas flow within the nozzle is quasi-one-dimensional isentropic flow of semi-perfect gas. A spray powder of copper is used. Mean diameter of copper powder 1, 5, 10, 15 @and 45ƒÊm are used. Working gas (is nitrogen) pressure and temperature at nozzle-intake are 3MPa and 350 ‹C. With decreasing particle diameter, calculated particle velocity at the nozzle exit increase immediately. So deposition efficiency increase immediately with decreasing particle diameter until 5ƒÊm. Abstract only; no full-text paper available.
Proceedings Papers
ITSC 2004, Thermal Spray 2004: Proceedings from the International Thermal Spray Conference, 358-362, May 10–12, 2004,
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In this study, experiments investigated the influence of substrate conditions such as substrate thickness, substrate surface conditions (blasted or polished), substrate temperature, number of overlaps and gun traverse speed on cold sprayed copper and titanium coatings. The influence of substrate thickness, substrate temperature and number of overlaps were different by materials of feedstock powder (copper and titanium). In another words, titanium deposition efficiency increase slightly while copper deposition efficiency decrease slightly with increasing the substrate thickness, the preheated substrate temperature and number of overlaps and gun traverse speed. On the other hands, both deposition efficiency of copper and titanium coating increase slightly with an increase in surface roughness from 0.2 μm Ra (polished surface) to 7 μm Ra (blasted surface). The deposition efficiency of titanium and copper decrease rapidly with increasing gun traverse speed.