Session: 03-08-02: Computational Modeling and Simulation for Advanced Manufacturing

Paper Number: 112993

112993 - Computational Modeling of Extreme Particles Deformation and Grain Refinement During Cold Spray Deposition 

The extreme deformation of particles during cold spraying reaches the critical state for dynamic recrystallization according to the literature and current simulation data, especially at regions near the particle interfaces. To encourage the development of equiaxed (softer) grains at the interface regions and improve the mechanical bond strength of cold spray coatings, the dynamic recrystallization of grains can be promoted via introducing hard Al₂O₃ particles in the feedstock powder. The recrystallization process is anticipated to be better understood through advanced simulations rather than experiments.Cold spraying can successfully deposit composite coatings with customized characteristics when deposition parameters are carefully set. To avoid conducting repeated experimental trials, numerical simulations are increasingly being used to optimize the cold spray deposition parameters. In cold sprayed coatings, the key factors that determine the effective properties of are the particle deformation, adhesion strength, porosity and grain size evolution, which largely depend on the process and material parameters. Consequently, tailoring the properties of the coating layer requires careful selection of essential process and material parameters that influence particles kinetic energy and thermal state, plastic deformation and strain-rate hardening. During cold spraying of composite layer, extreme particle deformation and temperature rise occurs due to the complex interactions among dissimilar particles; hence, the coating layer properties varies across the thickness. In the cold spray literature, the particle grain refinement is not considered in numerical simulation studies.

In the present study, a physics-based hybrid computational technique is used to simulate multi-material particles deformation during the cold spray deposition of Ni-Al2O3 coating utilized for wear applications. The hybrid approach effectively combines point cloud and finite element models to simulate particles deformation and interactions during the cold spray process. An attempt to predict the grain refinement due to extreme deformation and dynamic recrystallization of deformed particles is made for the first time using the phase field method (PFM). The strain field and temperature distribution are used to predict the grain size evolution in the deformed particles. The numerical simulation results are validated by comparing them with those of experiments. The results show that the softer Ni (matrix) particles undergo higher deformation, and their deformation pattern is strongly affected by the presence of neighboring Al2O3 particles. Particle’s deformation affects the grain size evolution, mainly in the Ni matrix material, due to higher plastic strain and strain rate. The extremely deformed regions, such as Ni particle interfaces and edges, demonstrate possibility for grain refinement according to simulation data on strain rate, temperature, and deformation among dissimilar particles. The goal of the current study is to establish a reliable numerical methodology for the optimization and prediction of properties of composite made from cold spraying.

Presenting Author: Abba Abubakar King Fahd University of Petroleum and Minerals

Presenting Author Biography: Education:

Post-Doc Mechanical Engineering Department, King Fahd University of Petroleum & Minerals, Dhahran
31261, Saudi Arabia, 2021.
Ph.D. Mechanical Engineering, King Fahd University of Petroleum & Minerals, Dhahran 31261, Saudi
Arabia, 2018
M.Sc. Mechanical Engineering, King Fahd University of Petroleum & Minerals, Dhahran 31261, Saudi
Arabia, 2014
B.Eng. Mechanical Engineering, Bayero University Kano, Kano 64-320, Nigeria, 2011

Research Areas:

Computational Mechanics
Thermal Spray Coatings
Cold Spray Coatings
Additive Manufacturing
Phase Field Modeling of Microstructure Evolution & Brittle Cracking
Design, Characterization and Synthesis of Composite Materials
Experimental Solid Mechanics
Droplet Dynamics
Renewable Energy Harvesting

Courses Taught:

ME 217: Material Science Laboratory
ME 307: Machine Design I
ME 475: Mechanical Behavior of Materials

Authors:

Abba Abubakar King Fahd University of Petroleum and Minerals
Khaled Al-Athel King Fahd University of Petroleum and Minerals
Syed Akhtar King Fahd University of Petroleum and Minerals