Thermo-Mechanical Deformation History and the Residual Stress Distribution in Cold Spray
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Thermo-Mechanical Deformation History and the Residual Stress Distribution in Cold Spray Enqiang Lin1 • Isaac Nault2 • Ozan C. Ozdemir1 • Victor K. Champagne Jr.2 Aaron Nardi2 • Sinan Mu¨ftu¨1
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Submitted: 4 December 2019 / in revised form: 16 March 2020 Ó ASM International 2020
Abstract In cold spray, high gas temperatures and high velocity impact of particles introduce complex thermal and stress histories in the coating layers and the substrate. It is crucial to understand the interplay between temperature evolution and residual stress development as the residual stresses could potentially cause distortion and/or delamination. In this study, a system-level cold-spray deposition model is developed. The model includes a moving heat source, material addition and thermo-mechanical stress analyses. The heat source model is first validated by qualitatively comparing the thermal history with experimental measurements from literature. The system-level model is then used to calculate the residual stresses and distortion in the cold-sprayed Cu/steel system. The influence of the spray path on the residual stress development is systematically analyzed. The corresponding interface residual stress states are also examined for the different spray paths. Simulation results indicate that the thermomechanical analysis using the developed system-level This article is part of a special topical focus in the Journal of Thermal Spray Technology on Advanced Residual Stress Analysis in Thermal Spray and Cold Spray Processes. This issue was organized by Dr. Vladimir Luzin, Australian Centre for Neutron Scattering; Dr. Seiji Kuroda, National Institute of Materials Science; Dr. Shuo Yin, Trinity College Dublin; and Dr. Andrew Ang, Swinburne University of Technology. & Sinan Mu¨ftu¨ [email protected]; [email protected] Enqiang Lin [email protected] 1
Department of Mechanical and Industrial Engineering, Northeastern University, Boston, MA 02115, USA
2
United States Army Research Laboratory, Aberdeen Proving Ground, Maryland 21005, USA
model can provide an effective way to assist in optimizing the cold-spray coating deposition strategy and improve the coating performance. Keywords cold spray heat transfer numerical simulation residual stress thermo-mechanical deformation List of Symbols e Emissivity r Boltzmann constant (1.3806 9 10-23 J/K) q Material density (kg=m3 ) Cp Specific heat capacity (J=kg K) k Thermal conductivity of the solid materials (W=m K) n Unit normal vector to the substrate surface fc ; fr Convective and radiative heat flux (W/m2) h Heat transfer coefficient used for forced convection (W=m2 K) hg Heat transfer coefficient used in Eq (6) (W=m2 K) Nu Nusselt number (Nu ¼ hg D=kg Þ D Nozzle diameter (m) Gas thermal conductivity (W=m K) kg Gas temperature on the substrate surface used in Tg Eq (6) (K) T Substrate temperature (K) T1 Air temperature (K) Ts Radiation reference temperature (K) _ Qimpact Thermal energy generation rate due to the particle impact (W=m3 ) _ Power of par
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