Gas Dynamics of Cold Spray & Control of Deposition
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1 Gas Dynamics of Cold Spray & Control of Deposition Ozan Ç. Özdemir, Christian A. Widener Advanced Materials Processing and Joining Laboratory South Dakota School of Mines and Technology 31 January 2017
2 Discovery and Technology Target Discovered in the 1980s at the Russian Academy of Sciences Line of sight process Coating thickness > 10 μm Extend expensive part life Structural and geometrical surface repair Crack growth prevention Coating of similar and dissimilar materials Corrosion prevention Additive-subtractive manufacturing 2
3 High Pressure Cold Spray System Aligned with Axis Converging Diverging Nozzle SoD Cold Spray Meter or Substrate Powder Feed Line SS316 Spray Gun PBI Nozzle 3
4 Nozzle Expansion ratio defines the Mach number of nozzle Expansion Ratio = Nozzle exit diameter 2 Nozzle throat diameter 2 Mach number changes throughout nozzle Mach = Gas Speed Speed of Sound = V gas γrt Gas velocity depends on gas inlet temperature 4
5 Substrate Substrate Gas Behavior Helium P = 900 psi T = 700 C Velocity Field Air Tungsten Helium P = 900 psi T = 700 C Thermal Field Air Tungsten 5
6 Gas Impingement and Standoff Distance Bow shock is stronger with lower standoff distances Increasing standoff distance causes falloff of particles Increased dispersion in the particle footprint 6
7 Substrate Gas Impingement Velocity Air Tungsten Nozzle 7
8 Substrate Gas Impingement Temperature 8
9 Particle Acceleration Particle drag generated by gas-particle velocity difference Accelerating particles Gas Flow Image Source: 9
10 Particulate Flow Video 1: 10
11 Bonding Criterion What makes particles stick? Particle impact velocity Size dependence 11
12 Deposition Video 2 Link: Video 3: Dense Coating Substrate 12
13 System & Equipment Control Gas Pressure Effects on Quality Powder Size Material Prep Standoff Distance How Far Away? Gas Air Nitrogen Helium Mixed Gas Gas Temperature Nozzle Material Geometry Substrate Surface Roughness Shape 13
14 Selecting Gas Impact Velocity = 1030 m/s Impact Velocity = 685 m/s cost of helium is 6 times that of nitrogen 14
15 Particle Size Nitrogen Helium 15
16 Powder Particle Size Selection Nitrogen Helium 16
17 Changing Gas Pressure Nozzle Conditions Velocity Temperature 17
18 Changing Gas Pressure Particle Impact Velocity Temperature 18
19 Changing Gas Temperature Nozzle Velocity Temperature 19
20 Changing Gas Temperature Particle Impact Velocity Temperature 20
21 Changing Nozzle Expansion Ratio Nozzle Velocity Temperature 21
22 Pressure Temperature Selection 22
23 Changing Nozzle Expansion Ratio Particle Impact Velocity Temperature 23
24 Changing Nozzle Length Nozzle Velocity Temperature 24
25 Changing Nozzle Length Particle Impact Velocity Temperature 25
26 Standoff Distance Nozzle Velocity Temperature 26
27 Standoff Distance Particle Impact Velocity Temperature 27
28 Powder Material Nozzle Velocity Temperature 28
29 Powder Material Particle Impact Velocity Temperature 29
30 Powder Material Aluminum Impact 30
31 Powder Material Titanium Impact 31
32 Powder Material Tantalum Impact 32
33 Powder Heat Treatment If we get 20% softening with heat treatment Particle testing with nanoindentation 33
34 Economics Total spray time Pressure and temperature optimization Deposition efficiency Deposition rate per volume of gas Nozzle throat diameter Powder feeding rate Gas mixing 34
35 Gas Mixing for Impact Control 0% He 10% He 30%He 50% He 70%He 35
36 Powder Feed Rate 36
37 Powder Feed Rate Particle Impact Velocity Temperature 37
38 Equipment Inspection and Alignment Nozzle Wear 38
39 Aligned vs Misaligned Aligned Misaligned Video 1: Video 4: 39
40 Small vs Large Feeder Tube Aligned Small Inner Diameter Aligned Large Inner Diameter Video 1: Video 5: 40
41 Guide to Deposition particle range: 10 μm to 100 μm in helium and nitrogen Sample: 50 μm aluminum particle sprayed with helium 41
42 Questions Ozan C. Ozdemir Graduate Research Assistant Ph.D. Candidate in Mechanical Engineering AMP Lab South Dakota School of Mines and Technology Tel: +1 (605) Christian A. Widener Director AMP Lab / AMPTECH & R3S Centers Associate Professor Mechanical/Materials Engineering Departments Tel: +1 (605) christian.widener@sdsmt.edu 42
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