PIV Validation of 3D Multicomponent Model for Cold Spray Within Nitrogen and Helium Supersonic Flow Field
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PIV Validation of 3D Multicomponent Model for Cold Spray Within Nitrogen and Helium Supersonic Flow Field M. Faizan-Ur-Rab1 • S. H. Zahiri2 • S. H. Masood1 • M. Jahedi2 • R. Nagarajah1
Submitted: 22 September 2016 / in revised form: 17 March 2017 / Published online: 22 May 2017 Ó ASM International 2017
Abstract This study presents the validation of a developed three-dimensional multicomponent model for cold spray process using two particle image velocimetry (PIV) experiments. The k-e type 3D model developed for spherical titanium particles was validated with the measured titanium particle velocity within a nitrogen and helium supersonic jet. The 3D model predicted lower values of particle velocity than the PIV experimental study that used irregularly shaped titanium particles. The results of the 3D model were consistent with the PIV experiment that used spherical titanium powder. The 3D model simulation of particle velocity within the helium and nitrogen jet was coupled with an estimation of titanium particle temperature. This was achieved with the consideration of the fact that cold spray particle temperature is difficult and expensive to measure due to considerably lower temperature of particles than thermal spray. The model predicted an interesting pattern of particle size distribution with respect to the location of impact with a concentration of finer particles close to the jet center. It is believed that the 3D model outcomes for particle velocity, temperature and location could be a useful tool to optimize system design, deposition process and mechanical properties of the additively manufactured cold spray structures. Keywords additive manufacturing cold spray computational fluid dynamics (CFD) particle image
& M. Faizan-Ur-Rab [email protected] 1
Swinburne University of Technology, Hawthorn, VIC 3122, Australia
2
CSIRO Manufacturing, Clayton, VIC 3168, Australia
velocimetry (PIV) three-dimensional (3D) model titanium particle
Introduction Cold spray is a high-speed solid-state deposition process in which powder particles travel with supersonic speed with a propellant gas flow are deposited onto a substrate after impact (Ref 1). The propellant gas, usually nitrogen or helium (Ref 2), is accelerated through a convergent-divergent de Laval nozzle to achieve supersonic speeds (Ref 3). Successful particle deposition onto a substrate is obtained when the impact velocity is greater than the critical velocity required for cold spray bond formation (Ref 4). In the cold spray process, optimization of critical parameters such as propellant gas pressure and temperature is vital to achieve the required velocity for successful solidstate deposition of particles (Ref 2). Particle image velocimetry (PIV) is an experimental technique that measures velocity by determining particle displacement over a short separation time (Ref 5). Pattison et al. (Ref 6) have investigated the effect of standoff distance and bow shock on aluminum, copper and titanium deposition using PIV. Recently, Li et
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