Powder Consolidation Using Cold Spray (eBook)

Preface 7
Acknowledgments 9
Contents 10
Nomenclature 13
1 Introduction 16
1.1 Cold Spray Coating-Basic Principals 16
1.2 Cold Spray Apparatus 17
1.3 Materials for Cold Spray 19
1.3.1 Metals 19
1.3.2 Metal Matrix Composites 23
1.3.3 Ceramics 25
1.3.4 Polymers 26
1.3.5 Nanostructured Powders 28
1.3.6 Path Forward 29
References 31
2 Experiments 35
2.1 Surface Treatment 35
2.1.1 Cold Spray Coating 35
2.1.2 Shot Peening 35
2.2 Characterization 36
2.2.1 Micro-Structural Observation 36
2.2.2 Hardness 36
2.2.3 XRD Measurement of Residual Stress 37
2.2.4 Roughness Measurement 40
2.2.5 Fatigue Test 42
2.2.6 Bond Strength and Tubular Coating Tensile Test 43
2.2.7 Contact Angle Measurement 45
References 45
3 Modeling Cold Spray 47
3.1 Impact Phenomenon: Lagrangian Approach 47
3.1.1 Background 47
3.1.2 Concluding Remarks 50
3.2 Impact Phenomenon: Hybrid Lagrangian-Analytical Approach 50
3.2.1 Analytical Model 51
3.2.2 Finite Element Simulation 54
3.2.3 Calculating Critical and Erosion Velocities 57
3.2.4 Results and Discussion 58
3.2.5 Concluding Remarks 63
3.3 Eulerian Simulation 64
3.3.1 Fundamental Assumption 65
3.3.2 Eulerian Model, Initial and Boundary Conditions 65
3.3.3 Material Behavior 66
3.3.4 General Deformation Behavior 67
3.3.5 Plastic Strain 69
3.3.6 Temperature 70
3.3.7 Material Flow Velocity 72
3.3.8 Discussion 73
3.3.9 Concluding Remarks 74
3.4 Damage Based Simulation of Consolidated Coating 75
3.4.1 Indentation Across Size Scales 75
3.4.2 Finite Element Model of Consolidated Coating 78
3.4.3 Results and Discussion 82
3.4.4 Concluding Remarks 86
References 87
4 Applications 90
4.1 Repair 90
4.1.1 Cavity Filling Using Cold Spray 92
4.1.2 Fatigue Behavior for Structural Applications 95
4.1.3 Hybrid Treatment for Fatigue Life Enhancement 101
4.2 Additive Manufacturing 112
4.2.1 Cold Spray, a Low Temperature, Solid State, Additive Manufacturing Process 114
4.2.2 Challenges 115
4.2.3 Concluding Remarks 117
4.3 Porous Coating/Cellular Structure by Subcritical Cold Spray 118
4.3.1 New Deposition Window for Cold Spray 119
4.3.2 Materials and Methods 119
4.3.3 Microscopic Observation 120
4.3.4 Cohesion Strength and Fracture Analysis 121
4.3.5 Surface Characterization 123
4.3.6 Concluding Remarks 124
4.4 Cold Spray to Mitigate Corrosion 124
4.4.1 Deposition Temperature and Pressure 125
4.4.2 Particle Size and Coating Thickness 127
4.4.3 Carrier Gas 128
4.4.4 Post Treatment 129
4.4.5 Co-Deposition of Metals/Alloys with Ceramics/Intermetallics 130
4.4.6 Path Forward 132
References 134