Significant influences of metal reactivity and oxide films at particle surfaces on coating microstructure in cold spraying

Based on large amount of experimental observations, the effects of metal reactivity and oxide films at particle surfaces on coating deposition behavior in cold spraying were presented and discussed. The oxygen contents in as-sprayed Ti, Ti-6Al-4V and Al coatings were higher than those in the corresponding starting powders. The obvious flashing jets outside nozzle exit during deposition of Ti and Ti-6Al-4V were caused by the reaction of the particles with oxygen in the entrained or the adopted air. For Ti and Ti-6Al-4V coatings, their porous structures are predominantly attributed to the surface reactivity (defined as reactivity with oxygen). This surface reaction could be helpful for formation of a metallurgical bonding between the deposited particles. For Al, even though it is more reactive than Ti, the oxide films at Al particle surfaces suppress the surface activity.     

Numerical investigations of the effect of oblique impact on particle deformation in cold spraying by the SPH method

In this study, a systematic examination of the oblique impacting of copper particles in cold spraying was conducted by using the smoothed particle hydrodynamics (SPH) method compared to the Lagrangian method. 3D models were employed owing to the asymmetric characteristic of the oblique impacting. It is found that in the oblique impact, the additional tangential component of particle velocity along the substrate surface could create a tensile force and decrease the total contact area and bonding strength between the particle and the substrate. The simulation results compare fairly well to the experiment results. Meanwhile, the asymmetric deformation can result in the focus of the shear friction on a small contact zone at one side, which may rise the interfacial temperature and thus facilitate the occurrence of the possible shear instability. Therefore, there probably exists an angle range, where the deposition efficiency may be promoted rather than the normal angle. Moreover, the particle deformation behavior simulated by the SPH method is well comparable to that simulated by the Lagrangian method and the experimental results, which indicates the applicability of the SPH method for simulating the impact process in cold spraying besides the previously used Arbitrary Lagrangian Eulerian (ALE) method.     

Some aspects on 3D numerical modeling of high velocity impact of particles in cold spraying by explicit finite element analysis

Three-dimensional modeling of particle impacting behavior in cold spraying by using ABAQUS/Explicit was conducted for copper and other materials. Various combinations of calculation settings concerning material damage, Arbitrary Lagrangian Eulerian adaptive meshing, distortion control and contact interaction were examined. The effects of meshing size and particle size on the impact behavior were analyzed compared to the previous results. The results show that the simulations with material damage cope well with the element excessive distortion and the resultant output is more reasonable than that obtained without material damage. In addition, the meshing size has less effect on the output with the material damage than without material damage. Although particle size has little effect on the morphologies of the deformed particles, it has some effect on the failure of elements at contact interfaces. The critical velocity for particle deposition could be estimated given the appropriate material properties.     

Deposition characteristics of Al-12Si alloy coating fabricated by cold spraying with relatively large powder particles

In this paper, the microstructure, microhardness and adhesive strength of Al-12Si coating produced by cold spraying were investigated. It is found that a thick, dense and well bonded Al-12Si coating could be produced by cold spraying with a relatively large powder through the control of spray conditions. The critical velocity for large Al-12Si particles was lower than that of small Al-12Si particles. The as-deposited Al-12Si coating had the same crystal structure as Al-12Si powder. The localized interface melting occurred resulting from both the adiabatic shearing upon impact and the thermal effect of hot gas. Some fine Si particles precipitated in α-Al matrix because of the thermal effect of hot gas during coating deposition. The dispersed Si particles in Al-12Si coating improved the coating microhardness.     

On high velocity impact of micro-sized metallic particles in cold spraying

In this study, a systematic examination of particle deformation behaviour in cold spraying was conducted for Cu particle using both the Lagrangian and Arbitrary Lagrangian Eulerian (ALE) methods. It is found that the meshing size in modelling by Largrangian method influences significantly the localized shear instability at interface areas. With refining the meshing size the onset velocity for interface shear instability decreases. The extrapolation of these results yields a reasonable critical velocity comparable to the actual one in cold spray practice. The results indicate that both the flattening ratio and compression ratio of the deformed particles increase with the increase in particle velocity, which are in good agreement with the experiment results. The ALE method provides a suitable way to examine the particle deformation in cold spraying. Moreover, the numerical results also show that there exists the similarity for the deformation of particles of different diameters.     

Influence of annealing treatment on the microstructure and mechanical performance of cold sprayed 304 stainless steel coating

In this study, 304 stainless steel coatings were deposited on interstitial-free steel substrate by cold spraying method. The effect of annealing treatment on microstructure, microhardness, ultimate tensile strength and fracture performance of the coatings were studied. The results showed that annealing treatment had made a dominant contribution to heal up the incomplete interfaces between the deposited particles. Both of the microstructure and the mechanical properties have been obviously optimized by annealing treatment. In addition, the coating microhardness decreased from 345 HV_0.2 for the as-sprayed coating to 201 HV_0.2 for the annealed coating. The coating ultimate tensile strength increased from 65 MPa for the as-sprayed coating to 357 MPa for the annealed coating, which resulted from the increase of the metallurgically bonded areas in the coating induced by annealing treatment. Fracture morphology of the coatings also revealed that annealing treatment changed the fracture character of the cold sprayed 304 stainless steel coating from brittle type to plastic type.     

Numerical simulation of deformation behavior of Al particles impacting on Al substrate and effect of surface oxide films on interfacial bonding in cold spraying

In this study, a comprehensive examination of the deformation behavior of Al particles impacting on Al substrate was conducted by using the Arbitrary Lagrangian Eulerian (ALE) method to clarify the deposition characteristics of Al powder and the effect of surface oxide films in cold spraying. It was found that the deformation behavior of Al particles is different from that of Cu particles under the same impact conditions owing to its lower density and thus less kinetic energy upon impact. The results indicated that a higher velocity was required for Al particles to reach the same compression ratio as that of Cu particles. On the other hand, the numerical results showed that the oxide films at particle surfaces influenced the deformation and bonding condition between the particle and substrate. The inclusions of the crushed oxide films at the interfaces between the depostied particles inhibit the deformation.     

Synthesis and microstructure observation of titanium carbonitride nanostructured coatings using reactive plasma spraying in atmosphere

In the present study, nanostructured titanium carbonitride (TiCN) coatings were successfully deposited by reactive plasma spraying (RPS) technology using a self-designed gas tunnel mounted on a normal plasma spray torch. The phase composition and microstructure of the TiCN coatings were characterised by XRD, SEM and TEM. The results indicated that the main phase of the coatings was FCC TiC_0.2N_0.8 with a small amount of Ti₃O. The coating that was deposited using 35 kW displayed better microstructure and properties. The coating exhibited a typical nanostructure including 90 nm diamertrical equiaxed grains and 400 nm long columnar grains by TEM images. The SEM observation further revealed that the equiaxed grains in parallel direction to the substrate surface in TEM images were actually the columnar grains perpendicular to the substrate surface. The formation mechanism of the nanostructured coatings was also discussed. The measured microhardness value of the coating was approximately 1659 Hv_100 g, and the calculated crack extension force was about 34.9 J/m².     

Effect of heat treatment on the microstructure and microhardness of cold-sprayed tin bronze coating

Tin bronze (TB) powder was deposited on a stainless steel substrate by cold spraying. Post-deposition heat treatment was conducted in an electrical resistance furnace under nitrogen atmosphere at a temperature of 850 °C for 3 h. The effect of heat treatment on the microstructure and microhardness of cold-sprayed TB coating was investigated. It was found that the as-sprayed TB coating presented a dense microstructure. Heat treatment significantly influenced the microstructure and microhardness of cold-sprayed TB coating. A distinguishable diffusion layer of about 150 μm was formed in the coating near the coating/substrate interface. A compound was precipitated in the diffusion layer. The microhardness in the coating was changed gradually along the coating from the interface to the coating surface after heat treatment. The microhardness in the diffusion layer was high owing to the precipitation of hard phase, while it was much low in other area due to the obvious grain growth during annealing.     

Effect of impact-induced melting on interface microstructure and bonding of cold-sprayed zinc coating

Zn particles are employed to create different impact conditions, including impact-induced interface melting in cold spraying. The influence of particle impact conditions on the interfacial microstructure evolution, microhardness and the bonding of particles in cold-sprayed Zn coatings are studied. An examination of coating surface morphology provides convincing evidence for melting at particle interfaces. The results reveal that the nanostructured phase was formed at the interface areas between deposited particles in coating resulting from the recrystallization of deformed grains. Melting at interfaces significantly enhances the bonding between the substrate and the coating and between the deposited Zn particles in the coating through the formation of a metallurgical bond. In addition, high driving gas temperature causes the decreasing hardness of deposited Zn coatings. The effects of particle conditions on the impact-induced melting and bonding mechanisms are discussed.     

Effect of substrate hardness on the deformation behavior of subsequently incident particles in cold spraying

A systematic finite element analysis (FEA) on the subsequently incident particles which refer to the particles depositing after the formation of the first layer coating is conducted in this study to clarify the bonding mechanism inside the cold sprayed coating. A simplified particle impact model is proposed and the simulated results based on this model demonstrate that substrate hardness exerts some effects on the deformation behavior of the subsequently incident particles. Hard substrate makes these particles deform intensively but using soft substrate enables them to achieve a slight deformation. At the same time, it is also found that substrate hardness plays its best role only when the formed coating is thin, as the development of the coating, the particle deformation behavior becomes more and more insensitive to the substrate hardness. The multi-particle impact simulation based on Eulerian method is also performed and reaches the same conclusion, confirming the accuracy of the simplified model. Besides, it is also found that when the velocity is increased to a hypervelocity, excessive deformation occurs in the formed coatings due to the impact of the subsequently incident particles.     

惯性约束聚变黑腔内等离子体界面处的动理学效应及其影响

在惯性约束聚变物理研究中,等离子体界面处的动理学效应及其时空演化特性近年来受到重点关注,因为它会显著影响激光能量沉积、激光等离子体不稳定性、辐照对称性、黑腔和内爆性能等诸多物理。准确描绘等离子体特征界面附近的动理学效应是惯性约束聚变物理设计的基本需求,也是高能量密度物理中的具有挑战且未完全解决的问题。重点回顾近几年来本团队围绕等离子体动理学效应及其影响开展的一些研究工作：（1）聚变黑腔中金等离子体与靶丸冕区等离子体边缘处的电场结构及其加速的高能离子对内爆对称性的影响;（2）激光光路上高Z-低Z等离子体界面处的电场产生机制及其导致的反常离子扩散对激光等离子体不稳定性的影响;（3）等离子体中电磁场结构的质子照相反演。     

Significant influence of particle surface oxidation on deposition efficiency, interface microstructure and adhesive strength of cold-sprayed copper coatings

The critical velocity for particle deposition in cold spraying is a key parameter, which depends not only on the material type, but also the particle temperature and oxidation condition. The dependency of deposition efficiency of cold spray Cu particles on the particle temperature and surface oxidation was examined. The effect of particle surface oxide scales on the interfacial microstructure and adhesive strength of the cold-sprayed Cu coatings was investigated. The results show that the deposition efficiency significantly increases with increasing the gas temperature but decreases with augmenting the oxygen content of the starting powder. The oxide inclusions at the interfaces between the deposited particles inhibit the effective bonding of fresh metals and remarkably lower the bond strength of the deposited Cu coatings on steel.     

Effect of arc spraying power on the microstructure and mechanical properties of Zn-Al coating deposited onto carbon fiber reinforced epoxy composites

This paper investigates the effect of arc spraying power on the microstructure and mechanical properties of Zn-Al coatings deposited on carbon fiber reinforced epoxy composites (CFRE composites). The bond strength between the Zn-Al coatings and the substrates was tested on a RGD-5 tensile testing machine. The microstructures and phase composition of the as-sprayed coatings were examined by scanning electron microscopy (SEM) and X-ray diffraction (XRD), respectively. The results showed that both the melting extent of Zn-Al particles and the bond strength of the coatings were evidently improved by increasing the spraying power. Moreover, the content of crystalline Zn-Al coatings was slightly changed. Observation of fracture surfaces showed that the Zn-Al coatings could bond well with the carbon fiber bundles using 40 kW spraying power.     

Preparation of ceramic coating on Ti substrate by Plasma electrolytic oxidation in different electrolytes and evaluation of its corrosion resistance

Ceramic oxide coatings (titania) were produced on Ti by micro-arc oxidation in different aluminate and carbonate based electrolytes. This process was conducted under constant pulsed DC voltage condition. The effect of KOH and NaF in aluminate based solution was also studied. The surface morphology, growth and phase composition of coatings were investigated using scanning electron microscope and X-ray diffraction. Corrosion behavior of the coatings was also examined by potentiodynamic polarization and electrochemical impedance spectroscopy. It was found that the sparking initiation voltage (spark voltage) had a significant effect on the form and properties of coatings. Coatings obtained from potassium aluminate based solution had a lower spark voltage, higher surface homogeneity and a better corrosion resistance than the carbonate based solution. Addition of NaF instead of KOH had improper effects on the homogeneity and adhesion of coatings which in turn caused a poor corrosion protection behavior of the oxide layer. AC impedance curves showed two time constants which is an indication of the coatings with an outer porous layer and an inner compact layer.     

惯性约束聚变X射线晶体衍射研究及最新进展

介绍了惯性约束聚变研究中X射线线谱诊断与各物理量之间关系,并对X射线晶体谱仪诊断方式及诊断原理进行了简要说明。针对不同类型诊断,介绍了常用不同类型衍射晶体的作用与原理。此外,介绍了最近开展的一种新型变锥面弯晶X射线诊断方法研究,此方法拥有高集光效率的同时,保证了后端接收装置的精巧耦合,减小了像差。以变锥面弯晶衍射特性研究为出发点,开发了一个X射线任意面型晶体衍射追迹仿真软件X-Chase,并以国内某大型激光装置类H、类He线的变锥面晶体诊断为例进行了计算演示,数值模拟结果显示了变锥面晶体具有很好的聚焦效果。     

ABC effect in double-pionic nuclear fusion and a pn resonance as its possible origin

A short overview over the ABC phenomenon is given,which is known since 50 years without any satisfactory explanation.On the basis of new exclusive and kinematically complete data obtained with the WASA detector at COSY we show that this phenomenon is linked with a resonant energy dependence in the total cross section of isoscalar double-pionic fusion processes.This resonance structure is connected with the baryon-baryon system,in particular with the pn and ΔΔ systems,however,has a mass,which is 90 MeV below the nominal ΔΔ threshold and a width of only 70 MeV,i.e.,five times smaller than expected from a conventional t-channel ΔΔ scenario.     

ABC effect in double-pionic nuclear fusion and a pn resonance as its possible origin

A short overview over the ABC phenomenon is given,which is known since 50 years without any satisfactory explanation.On the basis of new exclusive and kinematically complete data obtained with the WASA detector at COSY we show that this phenomenon is linked with a resonant energy dependence in the total cross section of isoscalar double-pionic fusion processes.This resonance structure is connected with the baryon-baryon system,in particular with the pn and ΔΔ systems,however,has a mass,which is 90 MeV below the nominal ΔΔ threshold and a width of only 70 MeV,i.e.,five times smaller than expected from a conventional t-channel ΔΔ scenario.     

Embedded particle size distribution and its effect on detonation in composite explosives

This paper discusses the effects of stochastically varying inert particle parameters on the long-term behaviour of detonation front propagation. The simulation model involves a series of cylindrical high explosive unit cells, each embedded with an inert spherical particle. Detonation shock dynamics theory postulates that the velocity of the shock front in the explosive fluid is related to its curvature. In our previous work, we derived a series of partial differential equations that govern the propagation of the shock front passing over the inert particles and developed a computationally efficient simulation environment to study the model over extremely long timescales. We expand upon that project by randomising several properties of the inert particles to represent experimental designs better. First, we randomise the particle diameters according to the Weibull distribution. Then we discuss stochastic particle spacing methods and their effects on the predictability of the shock wave speed. Finally, we discuss mixtures of plastic and metal particles and material inconsistency among the particles.     

Polarization dependent dispersion and its impact on optical parametric process in high nonlinear microstructure fibre

High nonlinear microstructure fibre （HNMF） is preferred in nonlinear fibre optics, especially in the applications of optical parametric effects, due to its high optical nonlinear coefficient. However, polarization dependent dispersion will impact the nonlinear optical parametric process in HNMFs. In this paper, modulation instability （MI） method is used to measure the polarization dependent dispersion of a piece of commercial HNMF, including the group velocity dispersion, the dispersion slope, the fourth-order dispersion and group birefringence. It also experimentally demonstrates the impact of the polarization dependent dispersion on the continuous wave supercontinuum （SC） generation. On one axis MI sidebands with symmetric frequency detunings are generated, while on the other axis with larger MI frequency detuning, SC is generated by soliton self-frequency shift.