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Monte Carlo Simulation of the Cold Spray Process of Mixtures of Metal and Ceramic Powders

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Abstract

During cold spraying of ceramic and metal mixtures, there is an interaction between the ceramic and metal particles during the spray process; as a result, under certain conditions, a non-monotonic dependence of deposition efficiency on the content of ceramic particles in the initial powder mixture is observed. In the present work, a numerical Monte Carlo model is put forward for the first time to simulate such behavior of deposition efficiency. The calculation results were compared with the available experimental data. It is shown that, with a proper choice of the values of involved model parameters, one can invent an adequate quantitative description of both the behavior of the deposition efficiency of the mixture and the behavior of the ceramic content of the coating. Additionally, the effects of particle size, particle size distribution, and deposition efficiency of pure metal powder are discussed.

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Abbreviations

\(c_{\rm V}\) :

Volumetric content of ceramic particles in powder

\(c_{\rm Vc}\) :

Volumetric content of ceramics in coatin

\(c_{\rm M}\) :

Mass (weight) content of ceramic particles in powder

\(d_{\rm p}\) :

Size of metal particles

\(d_{\rm cer}\) :

Size of ceramic particles

\({\rm DE}_{\rm mix}\) :

Deposition efficiency of powder mixture

\(p\) :

Probability of adherence of metal particles to non-activated surfaces, i.e., deposition efficiency of pure metal powder (without ceramic admixture)

\(p_{\rm a}\) :

Probability of adherence of metal particles to activated surfaces

\(p_{\rm cer}\) :

Probability of adherence of ceramic particles to metal surfaces

\(s_{\rm a1}\) :

Fraction of activated surface within the contact spot of a random metal particle with the coating surface

\(s_{\rm cer1}\) :

Fraction of ceramic surface within the contact spot of a random ceramic particle with the coating surface

\(\vartheta\) :

Probability of adherence of a random metal particle to the coating surface

\(\vartheta_{\rm cer}\) :

Probability of adherence of a random ceramic particle to the coating surface

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Acknowledgment

The reported study was funded by RFBR and ROSATOM, project number 20-21-00046 using equipment of the Joint-Use Center “Mechanics” of ITAM SB RAS.

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Authors and Affiliations

  1. Khristianovich Institute of Theoretical and Applied Mechanics, Siberian Branch of Russian Academy of Sciences (ITAM SB RAS), Institutskaya 4/1, Novosibirsk, Russia, 630090

    S. V. Klinkov & V. F. Kosarev

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Correspondence to V. F. Kosarev.

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Klinkov, S.V., Kosarev, V.F. Monte Carlo Simulation of the Cold Spray Process of Mixtures of Metal and Ceramic Powders. J Therm Spray Tech 30, 1081–1092 (2021). https://doi.org/10.1007/s11666-021-01176-0

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  • DOI: https://doi.org/10.1007/s11666-021-01176-0

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