computational framework development to investigate al matrix with low-velocity impact behavior at varied temperatures for cold spray composite coating design: al/tin case

Cold spray (cs) with metal matrix composite (mmc) is an alternative process for improving surface properties, which is crucial in plastic manufacturing. understanding of particle behavior during impact is required for cs. this study focused on developing a simplified computational framework using the single-shot particle impact model to predict the adherence of matrix particles in the low-velocity impact. in this work, the hardened skd11 coated with al matrix/tin reinforcement composite was selected, aiming to verify the proposed framework. al particle impact at different temperatures (300k, 623k, and 723k) under the low-velocity range of 350–600 m/s were simulated, revealing the particle temperature affects the cohesive area. as the particle temperature increases, the areas also increase under similar velocity. the flattening ratio was calculated from the simulation and found to be influenced by the particle velocity. the cs of pure al and al/tin (75:25 wt.%) on the hardened skd11 under 623k and 723k was carried out under the experiment with the estimated pressure based on the flattening ratio and particle behavior. the results suggest the coatings could be developed using estimated pressure. al/tin coating was deposited at different initial particle temperatures. results reveal that low coating porosity (<0.01%) could be obtained for both cases, and the higher particle temperature reveals higher thickness and %porosity, which agree well with the computational results. the developed framework shows high potential for designing cs for mmc coating, provided the reinforcement particles do not significantly affect the matrix particle flow or impact conditions.