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Production of titanium deposits by cold-gas dynamic spray: Numerical modeling and experimental characterization

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Abstract

Over the past five years, interest in cold-gas dynamics spraying (CGDS) has increased substantially. Considerable effort has been devoted to process development and optimization for such metals as copper and aluminium. This paper describes work undertaken to expand the understanding of the deposition of titanium by cold-spray methods. CGDS deposits have been produced from commercially pure titanium using room-temperature helium gas. The effect of different powder paticle size ranges, types of substrate, substrate preparation methods, and spray parameter conditions on powder deposition have been investigated. Microhardness testing of deposits was conducted, and their microstructures have been examined by scanning electron microscopy. Samples for pull-off bond-strength tests have been prepared from a number of the more promising sets of spray parameters and adhesive strengths determined. A one-dimensional numerical model of particle acceleration, employing isentropic gas flow behavior in the nozzle, has also been used to estimate particle exit velocities. This model explicitly addresses the dependence of the drag coefficient on gas compressibility and demonstrates its significance in terms of predicted particel velocities. By linking this model with the measured particle size distributions, estimates of particle velocity distributions at the nozzle exit plane have been computed. These allow an approximate value of the critical velocity for deposition of titanium to be made. Experimental observations on the microstructure and properties of the deposits are discussed in light of powder particle size and velocity distributions and the underlying physical and mechanical properties of the powders and substrates.

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Abbreviations

A :

cross-section area of nozzle, m2

A * :

throat area of nozzle, m2

A p :

surface area of the particle, m2

Bi:

biot number

C d :

drag coefficient

C g :

specific heat of the gas, J kg−1 K−1

C p :

specific heat of the particle, J kg−1 K−1

d p :

diameter of the particle, m

h :

heat-transfer coefficient, W m−2 K−1

M :

mach number of the gas

M c :

relative Mach number of the particle

m p :

mass of the particle, kg

Nu:

Nusselt number

R :

gas constant, J kg−1 K−1

Re:

Reynolds number of the particle

Pr:

Prandtl number

T g :

temperature of the gas, K

T p :

temperature of the particle, K

t :

time. s

v g :

velocity of the gas, m s−1

v p :

velocity of the particle, m s−1

γ:

specific heat ratio of the gas

λg :

thermal conductivity of the gas, W m−1 K−1

λp :

thermal conductivity of the particle, W m−1 K−1

μg :

dynamic viscosity of the gas, kg m−1 s−1

ρg :

density of the gas, kg m−3

ρp :

density of the particle, kg m−3

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Authors and Affiliations

  1. School of Mechancial, Materials and Manufacturing Engineering, University of Nottingham, University Park, NG7 2RD, Nottingham, UK

    T. Marrocco, D. G. McCartney & P. H. Shipway

  2. TW1, Granta Park, Great Abington, CB1 6AL, Cambridge, UK

    A. J. Sturgeon

Authors
  1. T. Marrocco
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  2. D. G. McCartney
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  3. P. H. Shipway
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  4. A. J. Sturgeon
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The original version of this paper was published in the CD ROM Thermal Spray Commects: Explore Its Surfacing Potential, International Thermal Spray Conference, sponsored by DVS, ASM International, and HW International Institute of Welding, Basel, Switzerland, May 2–4, 2005, DVS-Verlag GmbH, Düsseldorf, Germany.

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Marrocco, T., McCartney, D.G., Shipway, P.H. et al. Production of titanium deposits by cold-gas dynamic spray: Numerical modeling and experimental characterization. J Therm Spray Tech 15, 263–272 (2006). https://doi.org/10.1361/105996306X108219

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  • DOI: https://doi.org/10.1361/105996306X108219

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