Bonding mechanism in cold gas spraying

A one-dimensional dual-porosity model has been developed for the purpose of studying variably saturated water flow and solute transport in structured soils or fractured rocks. The model involves two overlaying continua at the macroscopic level: a macropore or fracture pore system and a less permeable matrix pore system. Water in both pore systems is assumed to be mobile. Variably saturated water flow in the matrix as well as in the fracture pore system is described with the Richards' equation, and solute transport is described with the convection-dispersion equation. Transfer of water and solutes between the two pore regions is simulated by means of first-order rate equations. The mass transfer term for solute transport includes both convective and diffusive components. The formulation leads to two coupled systems of nonlinear partial differential equations which were solved numerically using the Galerkin finite element method. Simulation results demonstrate the complicated nature of solute leaching in structured, unsaturated porous media during transient water flow. Sensitivity studies show the importance of having accurate estimates of the hydraulic conductivity near the surface of soil aggregates or rock matrix blocks. The proposed model is capable of simulating preferential flow situations using parameters which can be related to physical and chemical properties of the medium.

A dual-porosity model for simulating the preferential movement of water and solutes in structured porous media

The diffusive tortuosity of fine-grained unlithified sediments

Adiabatic shear instability based mechanism for particles/substrate bonding in the cold-gas dynamic-spray process

http://www.ucalgaryreservoirsimulation.ca/wp-content/uploads/2014/07/J27-1-s2.0-S0009250907003144-main.pdf

Critical review of the impact of tortuosity on diffusion

This paper presents an analytical model of the cold-spray process. By assuming a one-dimensional isentropic flow and constant gas properties, analytical equations are solved to predict the spray particle velocities. The solutions demonstrate the interaction between the numerous geometric and material properties. The analytical results allow determination of an optimal design for a cold-spray nozzle. The spray particle velocity is determined to be a strong function of the gas properties, particle material density, and size. It is also shown that the system performance is sensitive to the nozzle length, but not sensitive to the nozzle shape. Thus, it is often possible to use one nozzle design for a variety of operational conditions. Many of the results obtained in this article are also directly applicable to other thermal spray processes.

Gas Dynamic Principles of Cold Spray

This article presents experimental data and a computational model of the cold spray solid particle impact process. Copper particles impacting onto a polished stainless steel substrate were examined in this study. The high velocity impact causes significant plastic deformation of both the particle and the substrate, but no melting was observed. The plastic deformation exposes clean surfaces that, under the high impact pressures, result in significant bond strengths between the particle and substrate. Experimental measurements of the splat and crater sizes compare well with the numerical calculations. It was shown that the crater depth is significant and increases with impact velocity. However, the splat diameter is much less sensitive to the impact velocity. It was also shown that the geometric lengths of the splat and crater scale linearly with the diameter of the impacting particle. The results presented will allow a better understanding of the bonding process during cold spray.

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Impact of high velocity cold spray particles

Copper powder was sprayed by the cold gas-dynamic method. In-flight particle velocities were measured with a laser two-focus system as a function of process parameters such as gas temperature, gas pressure, and powder feed rate. Mean particle velocities were uniform in a relatively large volume within the plume and agreed with theoretical predictions. The presence of a substrate was found to have no significant effect on in-flight particle velocities prior to impact. Cold-spray deposition efficiencies were measured on aluminum substrates as a function of particle velocity and incident angle of the plume. Deposition efficiencies of up to 95% were achieved. The critical velocity for deposition was determined to be about 640 m/s for the system studied.

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Particle Velocity and Deposition Efficiency in the Cold Spray Process

The unique properties of coatings created by thermal spray deposition depend on the rapid solidification of individual splats created by impinging molten droplets. However, the impact process has been little studied because of the difficulty of measuring or numerically simulating the process, which occurs very quickly over a small area. Other scientific fields have investigated the impact of liquid droplets on solid surfaces. This paper reviews these studies, along with those conducted specifically on the thermal spray process. Modelers have almost universally ignored droplet solidification during impact; however, some experimental evidence suggests that the solidification process plays a significant role in splat formation. Splashing of impacting liquid droplets, another topic that has been largely ignored, affects deposition efficiency, porosity, and bond strength, and may also affect the amount of oxides incorporated in the coating. The scaling of data from impacting millimeter-size droplets traveling at low velocities to thermal spray conditions is questioned.

Review of impact and solidification of molten thermal spray droplets

It is widely held that most oxidation in thermally sprayed coatings occurs on the surface of the droplet after it has flattened. Evidence in this paper suggests that, for the conditions studied here, oxidation of the top surface of flattened droplets is not the dominant oxidation mechanism. In this study, a mild steel wire (AISI 1025) was sprayed using a high-velocity oxy-fuel (HVOF) torch onto copper and aluminum substrates. Ion milling and Auger spectroscopy were used to examine the distribution of oxides within individual splats. Conventional metallographic analysis was also used to study oxide distributions within coatings that were sprayed under the same conditions. An analytical model for oxidation of the exposed surface of a splat is presented. Based on literature data, the model assumes that diffusion of iron through a solid FeO layer is the rate limiting factor in forming the oxide on the top surface of a splat. An FeO layer only a few nanometers thick is predicted to form on the splat surface as it cools. However, experimental evidence shows that the oxide layers are typically 100× thicker than the predicted value. These thick oxide layers are not always observed on the top surface of a splat. Indeed, in some instances the oxide layer is on the bottom, and the metal is on the top. The observed oxide distributions are more consistently explained if most of the oxide forms before the droplets impact the substrate.

R. C. Dykhuizen

Papers

Gas Dynamic Principles of Cold Spray

Impact of high velocity cold spray particles

Particle Velocity and Deposition Efficiency in the Cold Spray Process

Review of impact and solidification of molten thermal spray droplets

Oxidation in wire HVOF-sprayed steel