Modeling Aspects of High Velocity Impact of Particles in Cold Spraying by Explicit Finite Element Analysis
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en-Ya Li, Chao Zhang, Chang-Jiu Li, and Hanlin Liao (Submitted January 15, 2009; in revised form March 24, 2009) In this study, an examination of cold spray particle impacting behavior using the ABAQUS/Explicit program was conducted for typical copper material (OFHC). Various combinations of calculation settings concerning element type, Arbitrary Lagrangian Eulerian adaptive meshing, contact interaction, material damage, etc., were examined with the main focus on the element excessive distortion and its effect on the resultant output. The effect of meshing size on the impact behavior was also clarified compared to the previous results obtained by using the LS-DYNA code. Some fundamental aspects on modeling of cold spray particle deformation are discussed.
Keywords
cold spraying, copper particles, deformation behavior, explicit finite element analysis, high velocity impact
1. Introduction Cold spraying is a coating technology on the basis of aerodynamics and high-speed impact dynamics. In this process, spray particles (usually 5-50 lm in diameter) are accelerated to a high velocity (typically 300-1200 m/s) by a high-speed gas flow that is generated through a convergent-divergent de Laval type nozzle. A coating is formed through the intensive plastic deformation of particles impacting on a substrate at a temperature well below the melting point of the spray material. This phenomenon has been discovered during the test of supersonic wind tunnel in the middle of 1980s at the Institute for Theoretical and Applied Mechanics of the Siberian Division of the Russian Academy of Science in Novosibirsk and firstly reported by the Russian scientists (Ref 1). It has been widely investigated by both numerical and experimental Wen-Ya Li, Shaanxi Key Laboratory of Friction Welding Technologies, School of Materials Science and Engineering, Northwestern Polytechnical University, 127, West Youyi Road, XiÕan, Shaanxi 710072, P.R. China; Chao Zhang, State key Laboratory for Mechanical Behavior of Materials, School of Materials Science and Engineering, XiÕan Jiaotong University, XiÕan, Shaanxi, P.R. China and LERMPS, Universite´ de Technologie de Belfort-Montbe´liard, Site de Se´venans, Belfort Cedex, France; and Chang-Jiu Li, State key Laboratory for Mechanical Behavior of Materials, School of Materials Science and Engineering, XiÕan Jiaotong University, XiÕan, Shaanxi, P.R. China; and Hanlin Liao, LERMPS, Universite´ de Technologie de Belfort-Montbe´liard, Site de Se´venans, Belfort Cedex, France. Contact e-mail: [email protected].
Journal of Thermal Spray Technology
methods owing to its advantages over the conventional thermal spray processes to deposit a wide variety of metals, alloys, and composites (Ref 2). Although it has great application potentials in aerospace, automobile manufacture, chemical industry, etc., there are still some important aspects to be well revealed including the actual bonding mechanism of spray particles. As for the bonding mechanism of cold spray particles, the most prevailing hypothesis is that plastic d
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