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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