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Meeting 2022 TMS Annual Meeting & Exhibition
Symposium Additive Manufacturing: Beyond the Beam III
Presentation Title Mesoscale simulation of cold spray microstructure formation
Author(s) Theron M. Rodgers, Jacob Mahaffey
On-Site Speaker (Planned) Theron M. Rodgers
Abstract Scope Cold spray deposition is a promising method of fabricating coatings and performing structural repairs with minimal heating of the deposited material or substrate. Cold spray coatings feature a complex microstructure that differs from both bulk materials and coatings generated by melting-based thermal spray processes (plasma spray, HVOF, etc). Significant progress in understanding single-particle impact dynamics has been made using hydrodynamic and molecular dynamics simulations, but there are no methods capable of simulating coating formation from repeated (> 1,000) particle impacts. Here we introduce a 3D rules-based simulation method for the generation of full-thickness synthetic coating microstructures. The method is based on a model developed for plasma spray processes but incorporates substrate deformation and erosion. In this presentation, the method will be introduced, its ability to simulate different deposition regimes discussed, and a comparison with experimental microstructures performed. SNL is managed and operated by NTESS under DOE NNSA contract DE-NA0003525
Proceedings Inclusion? Planned:
Keywords Additive Manufacturing, Surface Modification and Coatings, Computational Materials Science & Engineering

OTHER PAPERS PLANNED FOR THIS SYMPOSIUM

3D Binder-Jet Printed Metal Filters
A Multi-Step Data Driven Model for Reverse Shape Compensation for Binder Jet Parts
Additive Friction Stir Deposition of Al0.04CoCrFeNi High Entropy Alloy
Additive Manufacturing Assisted by Subtractive Sintering of Powder Components
Atomistic and Mesoscale Modeling of Sintering Kinetics in Solid-state Additive Manufacturing
Binder Jet Additive Manufactured H13: Microstructure Evolution and Properties
Cold spray processing of soft metals and hard steels
Coupled Fluid/Particle Dynamics Simulations for Binder Jetting Process
Demonstration of Strain Monitoring with Fiber Optics Embedded in SS304 with Ultrasonic Additive Manufacturing
Droplet-Powder Interactions in Binder Jetting: From Droplet to Line to Layer to Part
Effect of Laser Heating on Microstructure and Deposition Properties of Cold Sprayed SS304L
Effect of Powder Heat Treatment on Fatigue Performance of Free Standing AA7075 Cold Spray
Finite Element Analysis of High-strain-rate Deformation
FRICTION AND GRAVITY EFFECTS DURING SINTERING OF BINDER JET PARTS
Friction stir-based additive manufacturing techniques: Prospects and possibilities
Hydrogen Heat Treatment of Additively Manufactured Ti-6Al-4V for Improved Mechanical Properties
Impact of Grain Boundary Mobility on Decreasing Porosity in Metal Binder Jetting of Free-Sintering Low-Alloy Steel
In situ Observation of Melt Pool in Ultrasonic Vibration-Assisted Directed Energy Deposition
Influence of Hydrogen Content and Particle Size Distribution on the Microstructure of Tantalum Cold Spray Coatings
Interface formation during metal 3D printing: from individual droplets to 3D parts
Investigating process-structure-property relationships of 17-4 PH stainless steel fabricated via laser beam powder bed fusion (LB-PBF), laser powder directed energy deposited (LP-DED), and metal binder jetting (MBJ) methods
Material Flow and Microstructure Evolution during Additive Friction Stir Deposition of Aluminum Alloys
Mechanical Properties and Characterization of Solid-State Additive Manufacturing of AA6061 and AA5083
Mesoscale simulation of cold spray microstructure formation
Micro- and Nanostructural Evolution in AA7075 Manufactured by Additive Friction Stir Deposition
Microstructure and mechanical properties of friction stir deposited SS304
Microstructure Evolution Pathway in Solid-State Additive Manufacturing of Copper
MODELING OF EFFECT OF POWDER SPREADING ON GREEN BODY DIMENSIONAL ACCURACY IN ADDITIVE MANUFACTURING BY BINDER JETTING
Modeling Sintering Processes with Continuum Approaches
Optimization of Al 6061 Powder Feedstock for Cold Spray using a Through-Process Experimental Approach
Overview of the Process Fundamentals Underlying Additive Friction Stir Deposition
Parametric Study to Investigate the Sintering Behavior of Binder Jetted Oxide Ceramics
Practical Considerations for Complex Path Planning for Cold Spray Additive Manufacturing.
Print Parameter Effects on Porosity Distribution in Binder Jetting of WC-Co
Processing-structure-property correlation in additive friction stir deposited Ti-6Al-4V alloy from recycled metal chips
Processing and Characterization of Tantalum Powders for Cold Spray
Sintering Study of WC-17%Ni Cermets Processed By Binder Jet Additive Manufacturing
Temperature Influence on Microstructure and Mechanical Behavior During Deposition of Solid-State Additively Manufactured Aluminum Alloy 7050
Topological toughness in additively manufactured ceramic architected materials
X-ray Computed Tomographic Study of Density Gradients within Binder Jet Printed H13 Components

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