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The Effects of Contact Conditions on the Onset of Shear Instability in Cold-Spray

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Abstract

Using ABAQUS/Explicit, the effects of contact conditions between the particle and substrate, including tangential friction, normal constraint, and contact geometry on the plastic deformation during the cold-spray process are studied. It was found that the onset of shear instability, an event often used to indicate the establishment of bonding, is very sensitive to the choice of contact conditions. This suggests that the onset of shear instability does not serve as an accurate means to identify the plasticity threshold responsible for bonding. On the other hand, it is demonstrated that the evolution of the overall equivalent plastic strain (i.e., \(\overline{\text{PEEQ}}\)) and the overall von Mises stress, being linearly proportional to each other, are both independent of contact conditions. Furthermore, it is shown that an energy value, defined as the product of the \(\overline{\text{PEEQ}}\) and the von Mises stress integrated over all particle elements, can quantitatively represent the energy dissipated via plastic deformation while being independent of contact conditions. The \(\overline{\text{PEEQ}}\) and associated energy value as defined may provide robust tools to assess the plasticity and the consequent bonding during cold-spray.

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Notes

  1. This velocity is chosen so that the onset of shear instability can be observed and no excess deformation control is needed. Simulations with other particle velocities are also performed to verify that the results are not sensitive to the velocity value.

  2. The symmetric-to-asymmetric transition can occur spontaneously or can be easily triggered by a small random perturbation (see Supplementary Information for details).

  3. The axi-asymmetry is still present in the full-particle model without surface separation although it is much less visible.

  4. We note that thermal energy mostly comes from plastic deformation and the influence due to friction dissipation is rather negligible (see Supplementary Information for details).

  5. This linear relationship between overall stress state and overall strain state also holds before the onset of shear instability.

  6. The exact physics underlying the linearity however remains a bit unclear, due to the absence of analytical relation between overall stress state and overall strain state.

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Acknowledgments

We greatly thank the financial support from McGill Engineering Doctoral Award and National Sciences and Engineering Research Council (NSERC) of Canada. We also acknowledge Supercomputer Consortium Laval UQAM McGill and Eastern Quebec for providing computing power.

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Correspondence to Jun Song.

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Meng, F., Aydin, H., Yue, S. et al. The Effects of Contact Conditions on the Onset of Shear Instability in Cold-Spray. J Therm Spray Tech 24, 711–719 (2015). https://doi.org/10.1007/s11666-015-0229-z

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  • DOI: https://doi.org/10.1007/s11666-015-0229-z

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