Simulation of High Speed Impact in the Cold Spray Deposition Process
Jing XIE (INSA DE LYON), Daniel NELIAS (INSA Lyon), Helene WALTER-LE-BERRE (), Kiyohiro ITO (), Yuji ICHIKAWA (), Kazuhiro OGAWA ()
Contact Mechanics
Tue 10:45 - 12:15
Barus-Holley 163
In the Cold Spray deposition process, the spray particles (1-50m) are accelerated to a high velocity (300-1200m/s) by a high-speed gas flow, and then form a dense and high quality coating due to plastic deformation of particles impinged upon the solid surface of substrate. Successful interfacial bonding is believed to occur until the impact velocity reaches the critical velocity, which is the minimum velocity required to obtain sufficient kinetic energy to plastically deform the particle material. This work pays main attention on the deformation behavior of particle material, which was investigated by using the Coupled Eulerian Lagrangian (CEL) method. The capacities and reliabilities of this numerical method are discussed after comparison with other finite elements methods, i.e., Lagrangian, Arbitrary Lagrangian Eulerian and Smoothed Particles Hydrodynamics, and in light of some experimental data. The supersonic gas flow forms a strong bow shock on the substrate surface, resulting in an off-normal impact on the substrate. The deviation of particle trajectories from the center line can be so strong that some particles were washed away by the gas flow, causing the erosion of substrate under low impact angle circumstances. Simulation of erosion was firstly presented in this contribution. The coating formation was simulated based on a Face Center Cubic particles stack model, whose results closely related to the porosity rate of Cold Spray coating. The CEL numerical method has proven to be a powerful and efficient tool for non-linear transient analysis for problems encountering large deformation and high strain rates (up to 108 or 109 s1). The analysis of restitution coefficient indicated that it exists a critical erosion velocity ero. When the impact velocity is greater than ero, the particles would rebound, and produces erosion of the substrate surface simultaneously.