Finite element analyses of pure Ni cold spray particles impact related to coating crack behaviour

Abstract

ABSTRACTCold spray processing parameters governing particle velocity and impact energy are analysed in the present paper for pure Ni sprayed on IN718 substrates. The study is conducted by employing finite element modelling used to calculate the particle behaviour as a function of gas temperature and pressure and particles properties. In the present paper, the possibility of repairing cracks, in superalloys sheets, through cold spray is demonstrated. An IN718 panel, with a surface 30° V notch, was repaired with pure Ni particles via cold spray. The crack behaviour, of the V-notched sheets subjected to bending loading, was studied by FEM and mechanical experiments. Cold spray repair can contribute to the increase of the global fatigue life of cracked structures, in fact, the resistance of repaired panels is increased of more than eight times.