Table Of ContentSPRINGER BRIEFS IN APPLIED SCIENCES AND
TECHNOLOGY POLIMI SPRINGER BRIEFS
Atieh Moridi
Powder
Consolidation
Using Cold Spray
Process Modeling
and Emerging
Applications
123
SpringerBriefs in Applied Sciences
and Technology
PoliMI SpringerBriefs
Editorial Board
Barbara Pernici, Politecnico di Milano, Milano, Italy
Stefano Della Torre, Politecnico di Milano, Milano, Italy
Bianca M. Colosimo, Politecnico di Milano, Milano, Italy
Tiziano Faravelli, Politecnico di Milano, Milano, Italy
Roberto Paolucci, Politecnico di Milano, Milano, Italy
Silvia Piardi, Politecnico di Milano, Milano, Italy
More information about this series at http://www.springer.com/series/11159
http://www.polimi.it
Atieh Moridi
Powder Consolidation Using
Cold Spray
Process Modeling and Emerging Applications
123
AtiehMoridi
Department ofMaterials Science
andEngineering
Massachusetts Institute of Technology
Cambridge, MA
USA
ISSN 2191-530X ISSN 2191-5318 (electronic)
SpringerBriefs inApplied SciencesandTechnology
ISSN 2282-2577 ISSN 2282-2585 (electronic)
PoliMI SpringerBriefs
ISBN978-3-319-29961-7 ISBN978-3-319-29962-4 (eBook)
DOI 10.1007/978-3-319-29962-4
LibraryofCongressControlNumber:2016955785
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To my family.
For their constant support and unconditional
love.
I love you all dearly.
Preface
Cold spray (CS) is a process in which solid powders are accelerated in a de Laval
nozzletowardasubstrate.Iftheimpactvelocityexceedsathresholdvalue,particles
endure plastic deformation and adhere to the surface. Different materials such as
metals, ceramics, composites, and polymers can be deposited using cold spray,
creating a wealth of interesting opportunities toward harvesting particular proper-
ties. Cold spray is a novel and promising technology to obtain surface coating. It
offers several technological advantages over thermal spray since it utilizes kinetic
rather than thermal energy for deposition. As a result, tensile residual stresses,
oxidation, and undesired chemical reactions can be avoided. Development of new
material systems with enhanced properties covering a wide range of required
functionalities of surfaces and interfaces, from internal combustion engines to
biotechnology, has brought forth new opportunities for the cold spray with a rich
variety of material combinations.
The introductory chapter covers the basic principles of cold spray, different
apparatuses, and various material systems that have been studied so far. The latter
includes metals, ceramics, metal matrix composites, polymers, and nanostructured
powders. At the end of the chapter, a critical discussion on the future of this
technology is provided.
Chapter 2 describes the experimental procedures that are referred to in the
following chapters. Surface treatments, including cold spray coating and shot
peening (conventional and severe), are explained. Different experimental tech-
niques including optical and scanning electron microscopy, nano/microhardness
measurement, X-ray diffraction measurement of residual stress, roughness mea-
surement,rotatingbendingfatiguetest,coatingbondstrengthandcohesionstrength
tests and contact angle measurement are discussed in detail.
Chapter 3 presents different approaches to model cold spray process to extend
thecurrentunderstandingofitsfundamentalprinciples.Inthisregard,thefollowing
topics are discussed:
1. Assessment of critical and erosion velocities: To reveal the phenomenological
characteristic of interface bonding, Lagrangian simulation and occurrence
vii
viii Preface
of adiabatic shear instability, hybrid Lagrangian–analytical approach based on
energy calculations, and Eulerian simulation and material jet characteristics are
discussed.
2. Mechanical behavior of cold spray coatings: The first finite element scheme to
modelconsolidatedcoatingisproposed.Theeffectofmacroscopicdefectssuch
as interparticle boundaries and subsequent splat boundary cracking on
mechanical properties is discussed.
Chapter 4 demonstrates the applications of cold spray mainly on repairing
damaged parts, additive manufacturing, and corrosion protection in a variety of
disciplines, from aerospace to biomedical engineering. This includes a systematic
study of defect shape and the ability of cold spray to fill it, fatigue behavior of
coatings for structural applications, advantages and challenges of using cold spray
as an additive manufacturing process, a novel deposition window at subcritical
conditions to obtain porous coatings, and critical assessment of cold spray for
corrosion protection.
Cambridge, MA, USA Atieh Moridi
Acknowledgments
This book would not have been completed without a considerable amount of help
andsupportfromeveryonearoundme.Ifeeloverwhelminglygratefultowardthem,
and this is the smallest thing I could perhaps do to show my appreciation.
It gives me an immense debt of gratitude to express my sincere thanks to Prof.
Mario Guagliano, of politecnio di Milano for his excellent guidance, constant
encouragement, and critical comments.
IowemysinceregratitudetoProf.MingDao,fromtheDepartmentofMaterials
ScienceandEngineeringatMassachusettsInstituteofTechnologyforhisimmense
knowledge and critical comments.
Ihavebeengreatlyhelpedindoingthisbytheadviceandcriticalreadingsofthe
text by my colleague, Dr. Mostafa Hassani-Gangaraj. His scientific discussions,
constructive feedbacks, and intellectual input to my work are invaluable.
I am deeply thankful to Dr. Simone Vezzú from Veneto Nanotech for sharing
ideas and his generous support in doing cold spray depositions.
My sincere gratitude is to Prof. Thomas Klassen of the Helmut Schmidt
University, Germany. It was an honor to work with his group. I am especially
thankfultoProf.HamidAssadiandDr.FrankGärtnerwhoreadilytooktimeout
of their busy schedules to help me with the experimental tests.
SpecialthanksarealsoextendedtoProf.BertrandJodoinoftheUniversityof
Ottawa for his constructive suggestions.
My great appreciation goes to Eng. Michele Bandini, for his generous contri-
bution and performing shot peening at Peen Service.
A special mention should be made of the staff of C4, CLASD, and Origoni B
Labs, in particular, Pietro Pellin, Maurizio Pardi, Alessandro Tosi, Luca
Signorelli, and Francesco Cacciatore.
I would like to acknowledge the Nanomechanics Laboratory in the
Department of Materials Science and Engineering at MIT, for the facilities and
assistance that aided in completing this research.
ThefinancialsupportofPolitecnicodiMilanoandProgettoRocca(MIT-Italy
exchange program) is gratefully acknowledged.
ix
Contents
1 Introduction.... .... .... ..... .... .... .... .... .... ..... .... 1
1.1 Cold Spray Coating-Basic Principals .. .... .... .... ..... .... 1
1.2 Cold Spray Apparatus. ..... .... .... .... .... .... ..... .... 2
1.3 Materials for Cold Spray ... .... .... .... .... .... ..... .... 4
1.3.1 Metals... .... ..... .... .... .... .... .... ..... .... 4
1.3.2 Metal Matrix Composites . .... .... .... .... ..... .... 8
1.3.3 Ceramics. .... ..... .... .... .... .... .... ..... .... 10
1.3.4 Polymers. .... ..... .... .... .... .... .... ..... .... 11
1.3.5 Nanostructured Powders .. .... .... .... .... ..... .... 13
1.3.6 Path Forward.. ..... .... .... .... .... .... ..... .... 14
References.. .... .... .... ..... .... .... .... .... .... ..... .... 16
2 Experiments.... .... .... ..... .... .... .... .... .... ..... .... 21
2.1 Surface Treatment.... ..... .... .... .... .... .... ..... .... 21
2.1.1 Cold Spray Coating.. .... .... .... .... .... ..... .... 21
2.1.2 Shot Peening.. ..... .... .... .... .... .... ..... .... 21
2.2 Characterization . .... ..... .... .... .... .... .... ..... .... 22
2.2.1 Micro-Structural Observation .. .... .... .... ..... .... 22
2.2.2 Hardness. .... ..... .... .... .... .... .... ..... .... 22
2.2.3 XRD Measurement of Residual Stress ... .... ..... .... 23
2.2.4 Roughness Measurement.. .... .... .... .... ..... .... 26
2.2.5 Fatigue Test .. ..... .... .... .... .... .... ..... .... 28
2.2.6 Bond Strength and Tubular Coating Tensile Test .... .... 29
2.2.7 Contact Angle Measurement... .... .... .... ..... .... 31
References.. .... .... .... ..... .... .... .... .... .... ..... .... 31
3 Modeling Cold Spray .... ..... .... .... .... .... .... ..... .... 33
3.1 Impact Phenomenon: Lagrangian Approach. .... .... ..... .... 33
3.1.1 Background... ..... .... .... .... .... .... ..... .... 33
3.1.2 Concluding Remarks. .... .... .... .... .... ..... .... 36
xi
