Coupled Eulerian-Lagrangian (CEL) simulation of multiple particle impact during Metal Cold Spray process for coating porosity prediction

Song, Xu, Ng, Kai Lin, Chea, Jerome Ming Kai and Tan, Adrian Wei Yee , et al. (2020) Coupled Eulerian-Lagrangian (CEL) simulation of multiple particle impact during Metal Cold Spray process for coating porosity prediction. Surface and Coatings Technology, 385 (3), [125433]. (doi:10.1016/j.surfcoat.2020.125433).

Abstract

This work provides a robust and easy-to-use Coupled Eulerian-Lagrangian (CEL) framework for simulating multiple particle impact in the Metal Cold Spray (MCS) coating process. A hundred particles with various velocity, temperature and size, which follow the distributions observed in the experiment, have been generated using python script to represent the powder stream sprayed onto the substrate. Mesh convergence study was carried out to obtain the optimal element size, and sampling cuboid was implemented in the model to auto-calculate the porosity. The statistically-averaged macroscopic porosity obtained from simulation matched well with those from the experiment. With the validated model, prediction can be made to study the effect of the temperature and particle velocity on the coating porosity. It was found out that substrate temperature did not play major role in the coating porosity, while both particle temperature and velocity contributed significantly to the porosity change. With higher particle temperature and velocity, lower coating porosity can be obtained. In the end, preheating the powder was recommended as a practical solution to reduce the coating porosity as higher powder velocity resulted in nozzle clogging.

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