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Effect of Impact Angle on Ceramic Deposition Behavior in Composite Cold Spray: A Finite-Element Study

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Abstract

During the cold spraying of particle-reinforced metal matrix composite coatings (ceramic and metal particles mixture) on metal substrates, ceramic particles may either get embedded in the substrate/deposited coating or may rebound from the substrate surface. In this study, the dependence of the ceramic rebounding phenomenon on the spray angle and its effect on substrate erosion have been analyzed using finite-element analysis. From the numerical simulations, it was found that the ceramic particle density and substrate material strength played the major roles in determining the embedding and ceramic retention behavior. Substrate material erosion also influenced the ceramic retention, and the material loss increased as the impact angles decreased from normal. In general, the results concluded that decreasing the impact angle promoted the retention possibility of ceramics in the substrate. This study provides new theoretical insights into the effect of spray angles on the ceramic retention and suggests a new route toward optimizing the spraying process to increase the ceramic retention in composite coatings cold spray.

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Acknowledgments

We greatly thank the financial support from McGill Engineering Doctoral Award and National Sciences and Engineering Research Council (NSERC) of Canada. We also acknowledge Supercomputer Consortium Laval UQAM McGill and Eastern Quebec for providing computing power.

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Authors and Affiliations

  1. Department of Mining and Materials Engineering, McGill University, Montréal, QC, H3A 0C5, Canada

    Rohan Chakrabarty & Jun Song

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  1. Rohan Chakrabarty
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  2. Jun Song
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Correspondence to Jun Song.

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Chakrabarty, R., Song, J. Effect of Impact Angle on Ceramic Deposition Behavior in Composite Cold Spray: A Finite-Element Study. J Therm Spray Tech 26, 1434–1444 (2017). https://doi.org/10.1007/s11666-017-0604-z

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  • DOI: https://doi.org/10.1007/s11666-017-0604-z

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