Unraveling microforging principle during in situ shot-peening-assisted cold spray additive manufacturing aluminum alloy through a multi-physics framework
Cold spray (CS) is a highly potential solid-state additive manufacturing (AM) technique. In situ shot-peening-assisted CSAM was proposed to additively manufacture fully dense deposits using cost-effective and renewable nitrogen gas. The role of in situ shot-peening particles is critical but remains...
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| Published in | Materials & design Vol. 236; p. 112451 |
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| Main Authors | , , , , , , , , |
| Format | Journal Article |
| Language | English |
| Published |
Elsevier
01.12.2023
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| Subjects | |
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| Abstract | Cold spray (CS) is a highly potential solid-state additive manufacturing (AM) technique. In situ shot-peening-assisted CSAM was proposed to additively manufacture fully dense deposits using cost-effective and renewable nitrogen gas. The role of in situ shot-peening particles is critical but remains unclear. Here, the process was quantitatively modeled to visualize the dynamic deformation, energy conversion, as well as cell/sub-grain size and microhardness evolutions, compared to those during the conventional CSAM process, identifying the key role of in situ shot-peening particles in the AA6061 extreme deformation and microstructure characteristics during in situ shot-peening-assisted CSAM. High-fidelity modeling was verified fully by comparing the experimental and model-reproduced deformation profiles, cell/sub-grain size distributions, and increases in microhardness. The results show that the kinetic energy of in situ shot-peening particles was 470 times higher and dissipated mainly through AA6061 plastic deformation (86.36% of total energy), leading to significant enhancement of microhardness and tensile strength. Moreover, the mixing ratio of large-size SS410 particles required to create a fully dense deposit was evaluated from an energy perspective, in good agreement with the experiment. This study elucidates the microforging principle during in situ shot-peening-assisted CSAM, providing scientific guidelines for high-quality and low-cost CSAM of high-strength aluminum alloys. |
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| AbstractList | Cold spray (CS) is a highly potential solid-state additive manufacturing (AM) technique. In situ shot-peening-assisted CSAM was proposed to additively manufacture fully dense deposits using cost-effective and renewable nitrogen gas. The role of in situ shot-peening particles is critical but remains unclear. Here, the process was quantitatively modeled to visualize the dynamic deformation, energy conversion, as well as cell/sub-grain size and microhardness evolutions, compared to those during the conventional CSAM process, identifying the key role of in situ shot-peening particles in the AA6061 extreme deformation and microstructure characteristics during in situ shot-peening-assisted CSAM. High-fidelity modeling was verified fully by comparing the experimental and model-reproduced deformation profiles, cell/sub-grain size distributions, and increases in microhardness. The results show that the kinetic energy of in situ shot-peening particles was 470 times higher and dissipated mainly through AA6061 plastic deformation (86.36% of total energy), leading to significant enhancement of microhardness and tensile strength. Moreover, the mixing ratio of large-size SS410 particles required to create a fully dense deposit was evaluated from an energy perspective, in good agreement with the experiment. This study elucidates the microforging principle during in situ shot-peening-assisted CSAM, providing scientific guidelines for high-quality and low-cost CSAM of high-strength aluminum alloys. |
| ArticleNumber | 112451 |
| Author | Ma, Ninshu Zhang, Xian-Cheng Luo, Xiao-Tao Zhang, Mingxing Li, Chang-Jiu Wang, Qian Shi, Junmiao Geng, Peihao Huang, Wenjia |
| Author_xml | – sequence: 1 givenname: Qian surname: Wang fullname: Wang, Qian – sequence: 2 givenname: Ninshu surname: Ma fullname: Ma, Ninshu – sequence: 3 givenname: Junmiao surname: Shi fullname: Shi, Junmiao – sequence: 4 givenname: Wenjia surname: Huang fullname: Huang, Wenjia – sequence: 5 givenname: Xiao-Tao surname: Luo fullname: Luo, Xiao-Tao – sequence: 6 givenname: Peihao surname: Geng fullname: Geng, Peihao – sequence: 7 givenname: Mingxing surname: Zhang fullname: Zhang, Mingxing – sequence: 8 givenname: Xian-Cheng surname: Zhang fullname: Zhang, Xian-Cheng – sequence: 9 givenname: Chang-Jiu surname: Li fullname: Li, Chang-Jiu |
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