Experimental and Numerical Study of Al2219 Powders Deposition on Al2219-T6 Substrate by Cold Spray: Effects of Spray Angle, Traverse Speed, and Standoff Distance

Experimental and Numerical Study of Al2219 Powders Deposition on Al2219-T6 Substrate by Cold Spray: Effects of Spray Angle, Traverse Speed, and Standoff Distance

Materials

10.3390/ma16155240

http://dx.doi.org/10.3390/ma16155240

Zheng Zhang, Tzee Luai Meng, Coryl Jing Jun Lee, Fengxia Wei, Te Ba, Zhi-Qian Zhang, Jisheng Pan

General Materials Science

27 July 2023

Zhang, Z., Meng, T. L., Lee, C. J. J., Wei, F., Ba, T., Zhang, Z.-Q., & Pan, J. (2023). Experimental and Numerical Study of Al2219 Powders Deposition on Al2219-T6 Substrate by Cold Spray: Effects of Spray Angle, Traverse Speed, and Standoff Distance. Materials, 16(15), 5240. https://doi.org/10.3390/ma16155240

Cold spray (CS) is an emerging technology for repairing and 3D additive manufacturing of a variety of metallic components using deformable metal powders. In CS deposition, gas type, gas pressure, gas temperature, and powder feed rate are the four key process parameters that have been intensively studied. Spray angle, spray gun traverse speed, and standoff distance (SoD) are the other three process parameters that have been less investigated but are also important, especially when depositing on uneven substrates or building up 3D freeform structures. Herein, the effects of spray angle, traverse speed, and SoD during CS deposition have been investigated holistically on a single material system (i.e., Al2219 powders on Al2219-T6 substrate). The coatings’ mass gain, thickness, porosity, and residual stress have been characterized, and the results show that spray angle and traverse speed exercise much more effects than SoD in determining coatings’ buildup. Finite element method (FEM) modeling and computational fluid dynamic (CFD) simulation have been carried out to understand the effects of these three parameters for implementing CS as repairing and additive manufacturing using aluminum-based alloy powders.

Attribution 4.0 International (CC BY 4.0)

This research / project is supported by the Agency for Science, Technology and Research (A*STAR) - Singapore Aerospace Program
Grant Reference no. : A1915a0073

This research / project is supported by the Agency for Science, Technology and Research (A*STAR) - Singapore Aerospace Program
Grant Reference no. : A1915a0082

This research / project is supported by the Agency for Science, Technology and Research (A*STAR) - Structural Metal Alloy Program
Grant Reference no. : A18b1B0061

This research / project is supported by the Agency for Science, Technology and Research (A*STAR) - High-strength Lightweight Metals and Soft Magnetic Materials
Grant Reference no. : A1898b0043

This research / project is supported by the Agency for Science, Technology and Research (A*STAR) - Machining Learning Assisted Control of Metal Cold Spray and Shot Peening Processes
Grant Reference no. : A1894a0032

This research / project is supported by the Agency for Science, Technology and Research (A*STAR) - Advanced post-processing and non-destructive evaluation for additive manufacturing
Grant Reference no. : A20F9a0045

https://oar.a-star.edu.sg/communities-collections/articles/19230

1996-1944

Institute of Materials Research and Engineering