Numerical Simulation of the Cold Spray Deposition Process for Aluminium and Copper

2012 ◽  
Author(s):  
Jing Xie ◽  
Daniel Nelias ◽  
Hélène Walter-le Berre ◽  
Yuji Ichikawa ◽  
Kazuhiro Ogawa
Keyword(s):  
Reference Frame ◽  
Cold Spray ◽  
High Speed ◽  
Gas Flow ◽  
Heat Dissipation ◽  
Spray Deposition ◽  
Deposition Process ◽  
Arbitrary Lagrangian Eulerian ◽  
Systematic Analysis ◽  
The Impact

Cold spray is a rapidly developing coating technology for depositing materials in the solid state. In this deposition process, the spray particles are accelerated to a high velocity 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. 2D and 3D modelling of particle impacting behaviours in cold spray deposition process by using ABAQUS/Explicit was conducted for four couples of materials (i.e. impacting particle/impacted substrate): copper/aluminium, aluminium/copper, copper/copper, and aluminium/aluminium. A systematic analysis of a single impact was carried out considering different parameters, such as the initial impact velocity, initial temperature and contact angle, which affect the deposition process and subsequently the mechanical properties of coating. Three numerical methods have been evaluated and their performances are discussed for various simulation settings: (i) modelling in a Lagrangian reference frame; (ii) modelling using adaptive remeshing in an Arbitrary Lagrangian Eulerian (ALE) reference frame; and (iii), modelling in a CEL reference frame. It is found that the Coupled Eulerian Lagrangian (CEL) method has more advantages to simulate the large deformation of materials, and is also more efficient to prevent the excessive distortion of the mesh. A comparison between simulation results and experimental data from the literature was performed. Nevertheless, the CEL method is implicitly isothermal for ABAQUS v6.10, whereas the modelling in the classical Lagrangian reference frame does include coupled thermo-mechanical effects with a local increase of the temperature near the interface — due to friction — and for the highly plastically deformed elements — due to the heat dissipation linked to plasticity. A local rise of temperature at the impact surface may also be observed for oblique impacts. Finally a first attempt to simulate the deposition of several particles is made with a 3D CEL model, resulting in the creation of porosity at the interface between particles.

Interfacial Heat Transfer During Droplet Impact on a Solid Surface: Comparison of High-Resolution Laser Measurements With Finite-Element Simulations

2007 ◽  
Author(s):  
Rajneesh Bhardwaj ◽  
Jon P. Longtin ◽  
Daniel Attinger
Keyword(s):  
Heat Transfer ◽  
Fluid Dynamics ◽  
Finite Element ◽  
High Speed ◽  
Element Model ◽  
Deposition Process ◽  
Interfacial Heat Transfer Coefficient ◽  
Interfacial Heat Transfer ◽  
Laser Measurements ◽  
The Impact

The objective of this work is to understand the coupling of fluid dynamics and heat transfer during the impact of a millimeter-size water droplet on a flat, solid glass substrate. In this work, a finite-element model is presented which simulates the transient fluid dynamics and heat transfer during the droplet deposition process, considering Laplace forces on the liquid-gas boundary, and the dynamics of wetting. A novel, experimental laser-based method is used to measure temperatures at the solid-liquid interface. This method is based on a thermoreflectance technique and provides unprecedented temporal and spatial resolutions of 1 microsecond and 20 micrometer, respectively. Matching between simulations, temperature measurements and high-speed visualization allows the determination of the interfacial heat transfer coefficient.

Exploration of Enhanced Heat Dissipation Design for Brake Disc of High Speed Train

2010 ◽  
Author(s):  
Zhizhuang Yu ◽  
Yong Wang
Keyword(s):  
Thermal Load ◽  
High Speed ◽  
Gas Flow ◽  
Heat Dissipation ◽  
Brake Disc ◽  
Frictional Surface ◽  
Brake Shoe ◽  
Remarkable Effect ◽  
Gas Channel ◽  
Heat Transfer Theory

The function of the brake disc is to provide the ultimate guarantee of the safety of high speed trains. A braking unit includes two discs and two brake shoes. Braking performance depends on the pressure of the brake shoe and the friction between the disc and the shoe. When a train is braked, the brake disc endures a thermal load, which may affect the mechanical properties of the disc. If the thermal load exceeds the strength limit of the material, it could impact the safe running of the train. Therefore, the thermal load should be reduced as much as possible. Now the frictional surface of disc is plane and heat congregates easily in the surface area. The purpose of this paper is to explore a design for enhanced heat dissipation. A gas channel was used on the frictional surface to achieve the effect of heat dissipation. This design was analyzed by means of tribology and heat transfer theory. The distribution of gas flow was also researched. The temperature and stress field of the disc were simulated and analyzed. By the analysis it can be seen that the gas channel on the frictional surface of disc has a remarkable effect on heat dissipation in the brake disc.

scholarly journals Вплив діаметру частинок порошку нікелю на їх швидкість і температуру при холодному газодинамічному напилюванні

2021 ◽  
pp. 110-116
Author(s):  
Олександр Володимирович Шорінов ◽  
Сергій Олександрович Поливяний
Keyword(s):  
Particle Velocity ◽  
High Speed ◽  
Gas Flow ◽  
Particle Temperature ◽  
Cold Gas Dynamic Spraying ◽  
Optimal Size ◽  
Properties Of Coatings ◽  
Powder Particles ◽  
The Impact ◽  
Nozzle Inlet

To deposit coatings in cold gas-dynamic spraying (CS), a high-speed gas flow is used to accelerate and heat particles. Therefore, first of all, it is necessary to consider the general laws of the gas flow and the movement of particles in the flow, as well as its interaction with the substrate. Due to the CS process depends primarily on the particle velocity, it is important to understand the effect of the process parameters (pressure and temperature at the nozzle inlet), the characteristics of the powder particles (material density, shape, and size), and the geometry of the nozzle. The gas velocity limits the particle velocity that can be achieved with the CS process. Utilization of high gas pressure, long nozzles, and small particles lead to the fact that the particles move at a velocity close to the velocity of the gas, which can be increased by using gases with low molecular weight, as well as heating it. As a result of the analysis of theoretical and experimental methods for studying the cold spraying process, it was found that for coating formation velocity of powder particles needs to obtain a certain value (critical velocity), which depends on particle temperature at the impact, and density of the particle material. Numerical simulation of gas dynamics of a two-phase flow in CS nozzle and at the outlet from it for the range of air temperatures from 573 K to 873 K and constant pressure of 1,0 MPa has been carried out. The influence of the diameter of nickel powder particles on their temperature and velocity at impact was investigated. Numerical simulations were performed for a range of particle diameters from 5 to 30 μm. In the future, the results obtained can be used to find the optimal size of the powder particles under certain spraying conditions, to calculate the critical particle velocity, and also to develop the window of deposition. This will make it possible to select the optimal parameters of the gas flow at the nozzle inlet (pressure and temperature), which are guaranteed to ensure the adhesion of particles to the substrate and the formation of coatings. Also, the results obtained can be used to predict the properties of coatings, as well as to achieve maximum deposition efficiency of the CS process.

Simulation of the Cold Spray Deposition Process for Aluminum and Copper using Lagrangian, ALE and CEL Methods

2014 ◽  
pp. 321-358 ◽  
Author(s):  
Daniel Nélias ◽  
Jing Xie ◽  
Hélène Walter-Le Berre ◽  
Yuji Ichikawa ◽  
Kazuhiro Ogawa
Keyword(s):  
Cold Spray ◽  
Spray Deposition ◽  
Deposition Process

Numerical Modeling of Hydrodynamic Impact and Local Slamming Effects

2015 ◽  
Author(s):  
Ali Mohtat ◽  
Ravi Challa ◽  
Solomon C. Yim ◽  
Carolyn Q. Judge
Keyword(s):  
Numerical Method ◽  
Impact Velocity ◽  
High Speed ◽  
Impact Behavior ◽  
Analytical Prediction ◽  
Arbitrary Lagrangian Eulerian ◽  
Hydrodynamic Impact ◽  
Ale Formulation ◽  
Wide Range ◽  
The Impact

Numerical simulation and prediction of short duration hydrodynamic impact loading on a generic wedge impacting a water free-surface is investigated. The fluid field is modeled using a finite element (FE) based arbitrary Lagrangian-Eulerian (ALE) formulation and the structure is modeled using a standard Lagrangian FE approximation. Validation of the numerical method against experimental test data and closed form analytical solutions shows that the ALE-FE/FE continuum approach captures the impact behavior accurately. A detailed sensitivity analysis is conducted to study the role of air compressibility, deadrise angle, and impact velocity in estimation of maximum impact pressures. The pressure field is found to be insensitive to air compressibility effect for a wide range of impact velocities and deadrise angles. A semi-analytical prediction model is developed for estimation of maximum impact pressures that correlates deadrise angle, impact velocity, and a nonlinear interaction term that couples hydrodynamic effects between these parameters. The numerical method is also used to examine the intrinsic physics of water impact on a high-speed planing hull with the goal of predicting slamming loads and resulting motions.

Brain Deformation in Linear Head Impact

2009 ◽  
Author(s):  
Kaveh Laksari ◽  
Kurosh Darvish
Keyword(s):  
Finite Element ◽  
High Speed ◽  
Single Point ◽  
Arbitrary Lagrangian Eulerian ◽  
Brain Deformation ◽  
Ale Formulation ◽  
Point Integration ◽  
Inertial Loading ◽  
Experimental Values ◽  
The Impact

In this study, a 2D model of the head underwent linear impact and the experiments were simulated by finite element models. A cylinder with a diameter of 100mm and height of 20mm was filled with 5% gelatin, which was used as the brain surrogate material. The physical model was mounted onto a High Speed Computer Controlled Impact System to generate inertial loading of approximately 50 G average deceleration. The deformation of the samples was studied through image processing. Finite element (FE) analysis was used to simulate the experiments. The impact tests were modeled with two methods: a Lagrangian formulation with single point integration and an Arbitrary Lagrangian Eulerian (ALE) formulation with single point integration and void using LS-Dyna FE code. In the model with slip contact, the normal and shear strains reached more than 20% in some regions, which confirmed the risk of axonal injury in the linear impacts applied in this study. It was seen that in the Lagrangian models, in order to stabilize the simulation, high bulk moduli needed to be used; however, this resulted in much smaller void generation in the posterior region of the model. It was shown that the void generation reaches the experimental values by introducing 1–2 mm initial gaps between brain and skull. The ALE model was more stable and less sensitive to the bulk modulus, but showed smaller deformations.

scholarly journals Theoretical Uniformity Analysis and Improvement of Spray Deposition by Mixing Nozzles with Heating Conditions

Coatings ◽  
2020 ◽  
Vol 10 (1) ◽  
pp. 81
Author(s):  
Xuran Dong ◽  
Xiaolong Pan ◽  
Xianxian Gao ◽  
Haisheng Fang
Keyword(s):  
High Speed ◽  
Heating Temperature ◽  
Spray Deposition ◽  
Low Cost ◽  
Spray Coating ◽  
Deposition Process ◽  
Test Method ◽  
Large Area ◽  
Orthogonal Test Method ◽  
Experimental Trials

Spray coating is widely used in the manufacture of deposited layers of electronic devices due to its unique advantages of high-speed deposition over a large area. To improve the spray deposition process for further low-cost and uniform production, the uniformity of the spray deposition should be systematically investigated. The current study, however, mainly focuses on the experimental trials with few numerical directions especially for the mixing nozzle sprayers with heating conditions. In the paper, we conduct a theoretical study on the uniformity of the internal and external mixing nozzles. The influencing factors include the initial angle, the total ink flow rate, the transporting gas velocity and the distance from the nozzle to the substrate. Then, the orthogonal test method is adopted to obtain the optimal combination of the parameters. Finally, the effects of different heating modes on the uniformity have been further studied. The results show that these factors influence the uniformity with the two types of nozzles to a different degree. The evaporation of the atomized droplets can effectively improve the uniformity in a certain temperature range. The heating temperature with the highest uniformity is various depending on the heating modes, which should be carefully addressed during the actual production.

Microstructure and Mechanical Properties of Spray Deposited W9Mo3Cr4V High Speed Steel

2011 ◽  
Vol 391-392 ◽  
pp. 714-718
Author(s):  
Rui Zhou ◽  
Jian Fei Sun ◽  
Ying Jun Yang
Keyword(s):  
Mechanical Properties ◽  
Impact Toughness ◽  
High Speed ◽  
Bending Strength ◽  
Spray Deposition ◽  
High Speed Steel ◽  
Solidification Shrinkage ◽  
Microstructure And Mechanical Properties ◽  
The Matrix ◽  
The Impact

Microstructure and mechanical properties of W9Mo3Cr4V high speed steel fabricated by spray deposition have been studied. Spray deposited W9Mo3Cr4V high speed steel has a typical equiaxed structure which is finer and more homogeneous with a grain size of 20-30 micrometer compared with conventional casted counterparts. There are pores in the matrix of the deposited steel, which involve gas porosity, filling porosity and solidification shrinkage. As-deposited high speed steel is mainly composed of martensite, austenite and carbides which comprise MC carbide and M6C carbide. Mechanical properties show that the hardness and bending strength of the as-deposited steel are higher than that of the conventionally casted ones. However, impact toughness of the high speed steel is lower than that of the conventionally casted steel, which can be attributed to the existence of porosities and M6C carbides which reduce the impact toughness of high speed steels.

scholarly journals Structure and Properties of Cold Spray Coatings

2010 ◽  
Vol 654-656 ◽  
pp. 1880-1883 ◽  
Author(s):  
Kevin Spencer ◽  
Vladimir Luzin ◽  
Ming Xing Zhang
Keyword(s):  
Cold Spray ◽  
Spray Deposition ◽  
Deposition Process ◽  
Light Metal ◽  
Structure And Properties ◽  
Coating Materials ◽  
Surface Protection ◽  
Spray Coatings ◽  
The Subject ◽  
Stress Profiles

Cold spray coatings are considered promising for surface protection of light metal substrates but the mechanisms of bonding and coating build-up are still poorly understood and are the subject of continuing debate. A variety of coating/substrate combinations have been characterised in detail using electron microscopy to examine the nature of the interparticle and particle/substrate interfaces. Through-thickness residual stress profiles obtained via neutron diffraction show that the internal stress varies significantly depending on the coating materials. The work will present a picture of the cold spray deposition process using different material examples.

Numerical Approximation of Fluid Structure Interaction (FSI) Problem

2013 ◽  
Author(s):  
Bhuiyan Shameem Mahmood Ebna Hai
Keyword(s):  
High Speed ◽  
Fluid Structure Interaction ◽  
Navier Stokes ◽  
Arbitrary Lagrangian Eulerian ◽  
Fluid Structure ◽  
Structure Interaction ◽  
Reinforced Plastics ◽  
Advanced Composite Materials ◽  
Special Cases ◽  
The Impact

Nowadays, advanced composite materials such as carbon fiber reinforced plastics (CFRP) are being applied to many aircraft structures in order to improve performance and reduce weight. Most composites have strong, stiff fibres in a matrix which is weaker and less stiff. However, aircraft wings can break due to Fluid-Structure Interaction (FSI) oscillations or material fatigue. The airflow around an airplane wing causes the wing to deform, while a wing deformation causes a change in the air pattern around it. Due to thrust force, turbulent flow and high speed, fluid-structure interaction (FSI) is very important and arouses complex mechanical effects. Due to the non-linear properties of fluids and solids as well as the shape of the structures, only numerical approaches can be used to solve such problems. The principal aim of this research is to explore and understand the behaviour of the fluid-structure interaction during the impact of a deformable material (e.g. an aircraft wing) on air. This project focuses on the analysis of Navier-Stokes and elastodynamic equations in the arbitrary Lagrangian-Eulerian (ALE) frameworks in order to numerically simulate the FSI effect on a double wedge airfoil. Since analytical solutions are only available in special cases, the equation needs to be solved by numerical methods. Of all methods, the finite element method was chosen due to its special characteristics and for its implementation, the software package DOpElib.

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