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Finite Element Modeling of Single-Particle Impacts for the Optimization of Antimicrobial Copper Cold Spray Coatings

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Abstract

Prior work has demonstrated greater antipathogenic efficacy concerning the nanostructured copper cold spray coatings versus conventional copper cold spray coatings, while both the nanostructured and conventional cold spray coatings maintain greater contact killing/inactivation rates relative to other thermal spray deposition methods. Recent work has more heavily focused upon the nanostructured cold spray coatings greater efficacy. However, the antimicrobial efficacy of conventional copper cold spray coatings may be improved upon by way of identifying processing parameters that yield microstructures with the greatest concentration of atomic copper ion diffusion pathways. Since ideal processing parameters for a given application can be computed in silico via finite element analysis methods, the fundamental computational frameworks for doing so using the Johnson–Cook and Preston–Tonks–Wallace plasticity models. Modeled single-particle impact morphology outputs were compared with experimental microstructures using scanning electron microscopy and optical microscopy. The computed von Mises flow stresses associated with the two plasticity models were compared with traditionally static nanoindentation data as well as dynamic spherical nanoindentation stress–strain curves. Continued work with the finite element analysis framework developed herein will enable the best cold spray parameters to be identified for optimized antimicrobial properties as a function of deformation-mediated microstructures while still maintaining the structural integrity of the deposited material. Subsequent work will extend the finite element analysis models to multi-particle impacts when spray-dried and gas-atomized copper powder particles have been appropriately meshed.

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Acknowledgments

We are grateful to Christopher J. Massar of Worcester Polytechnic Institute for his insightful comments and feedback on an earlier draft of the paper. This research was funded by U.S. Army Research Laboratory, Grant Number W911NF-10-2-0098.

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Authors and Affiliations

  1. Raytheon Technologies, Waltham, MA, 02451, USA

    Kristin Sundberg

  2. Materials Science and Engineering, Worcester Polytechnic Institute, Worcester, MA, 01609, USA

    Bryer C. Sousa, Richard D. Sisson Jr. & Danielle L. Cote

  3. Applied Research Laboratory, Pennsylvania State University, State College, PA, 16801, USA

    Jeremy Schreiber & Timothy J. Eden

  4. Solvus Global LLC, 104 Prescott St, Worcester, MA, 01605, USA

    Caitlin E. Walde

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  1. Kristin Sundberg
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Sundberg, K., Sousa, B.C., Schreiber, J. et al. Finite Element Modeling of Single-Particle Impacts for the Optimization of Antimicrobial Copper Cold Spray Coatings. J Therm Spray Tech 29, 1847–1862 (2020). https://doi.org/10.1007/s11666-020-01093-8

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