Abstract
The cold spray coating process involves many process parameters which make the process very complex, and highly dependent and sensitive to small changes in these parameters. This results in a small operational window of the parameters. Consequently, mathematical optimization of the process parameters is key, not only to achieving deposition but also improving the coating quality. This study focuses on the mathematical identification and experimental justification of the optimum process parameters for cold spray coating of titanium alloy with silicon carbide (SiC). The continuity, momentum and the energy equations governing the flow through the low-pressure cold spray nozzle were solved by introducing a constitutive equation to close the system. This was used to calculate the critical velocity for the deposition of SiC. In order to determine the input temperature that yields the calculated velocity, the distribution of velocity, temperature, and pressure in the cold spray nozzle were analyzed, and the exit values were predicted using the meshing tool of Solidworks. Coatings fabricated using the optimized parameters and some non-optimized parameters are compared. The coating of the CFD-optimized parameters yielded lower porosity and higher hardness.
Highlights
IntroductionTi-6Al-4V is an alloy of titanium that is characterized by excellent bulk mechanical and chemical properties such as very good strength-to-weight ratio (due to low density), high specific strength, low elastic modulus, superior resistance to both corrosion and erosion in many environments, excellent high temperature resistance, and biocompatibility
Ti-6Al-4V is an alloy of titanium that is characterized by excellent bulk mechanical and chemical properties such as very good strength-to-weight ratio, high specific strength, low elastic modulus, superior resistance to both corrosion and erosion in many environments, excellent high temperature resistance, and biocompatibility
The results showed that besides materials properties, the critical velocity was significantly influenced by the oxidation condition of the particles
Summary
Ti-6Al-4V is an alloy of titanium that is characterized by excellent bulk mechanical and chemical properties such as very good strength-to-weight ratio (due to low density), high specific strength, low elastic modulus, superior resistance to both corrosion and erosion in many environments, excellent high temperature resistance, and biocompatibility. Few literatures are available on mathematical study and optimization of cold spray process parameters [18,19,21], as far as the authors of this work are aware, Computational Fluid Dynamics (CFD) analysis of input temperature to determine the critical velocity, which is the object of this investigation, has not been reported in the literature. The investigation consists of the following parts: (1) statistical computation of the critical velocity for cold spray coating of titanium alloy with This was done by using a constitutive equation to solve the continuity, momentum, and energy a constitutive equation to solve the continuity, momentum, and energy equations governing the equations governing fluidused inside the LPCS de Lava nozzle used in the LPCS (2).
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