Publications

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Plasma sprays can be used to melt particles, which may be deposited on an engineered surface to apply unique properties to the part. Because of the extreme temperatures (>>3000ºC) it is desirable to conduct the process in a way to avoid melting the parts to which the coatings are being applied. A jet of ambient gas is sometimes used to deflect the hot gases, while allowing the melted particles to impact and adhere to the substrate. This is known as a plume quench. While plume quenching is done in practice, to our knowledge there have not been any studies on how to apply a plume quench, and how it may affect the flows. We have recently adapted our fire simulation tool to simulate argon plasma sprays with a variety of metal particles. Two nozzle conditions are considered, with very different gas flow and power conditions. Two particle types are considered, Tantalum and Nickel. For the model, the k-epsilon turbulence model is compared to a more dynamic TFNS turbulence model. Limited data comparisons suggest the higher-fidelity TFNS model is significantly more accurate than the k-epsilon model. Additionally, the plume quench is found to have a noticeable effect for the low inlet flow case, but minimal effect on the high flow case. This suggests the effectiveness of a quench relates to the relative momentum of the intersecting gas jets.

Thermal spray processing of metals and respective blends is becoming increasingly attractive due to the unique properties such as increased yield strength, low ductility, and differences in tensile and compressive strengths that result from microstructural features due to the spray process compared to other additive manufacturing methods. Here we report the results of plate impact experiments applied to Controlled Atmosphere Plasma Spray deposits of tantalum (Ta), niobium (Nb), and a tantalum-niobium blend (TaNb). These methods allowed for definition of the Hugoniot for each material type and the assessment of the Hugoniot Elastic Limit (HEL). Spallation experiments were conducted, and soft recovery of each material type allowed for scanning electron microscopy to characterize the fracture mechanism during tensile loading.

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Spray-formed materials have complex microstructures which pose challenges for microscale and mesoscale modeling. To constrain these models, experimental measurements of wave profiles when subjecting the material to dynamic compression are necessary. The use of a gas gun to launch a shock into a material is a traditional method to understand wave propagation and provide information of time-dependent stress variations due to complex microstructures. This data contains information on wave reverberations within a material and provides a boundary condition for simulation. Here we present measurements of the wavespeed and wave profile at the rear surface of tantalum, niobium, and a tantalum/niobium blend subjected to plate impact. Measurements of the Hugoniot elastic limit are compared to previous work and wavespeeds are compared to longitudinal sound velocity measurements to examine wave damping due to the porous microstructure.

Thermal spray processes involve the repeated impact of millions of discrete particles, whose melting, deformation, and coating-formation dynamics occur at microsecond timescales. The accumulated coating that evolves over minutes is comprised of complex, multiphase microstructures, and the timescale difference between the individual particle solidification and the overall coating formation represents a significant challenge for analysts attempting to simulate microstructure evolution. In order to overcome the computational burden, researchers have created rule-based models (similar to cellular automata methods) that do not directly simulate the physics of the process. Instead, the simulation is governed by a set of predefined rules, which do not capture the fine-details of the evolution, but do provide a useful approximation for the simulation of coating microstructures. Here, we introduce a new rules-based process model for microstructure formation during thermal spray processes. The model is 3D, allows for an arbitrary number of material types, and includes multiple porosity-generation mechanisms. Example results of the model for tantalum coatings are presented along with sensitivity analyses of model parameters and validation against 3D experimental data. The model's computational efficiency allows for investigations into the stochastic variation of coating microstructures, in addition to the typical process-to-structure relationships.

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Solid-state cold spraying (CS) of metals and respective blends is becoming increasingly attractive compared to conventional high temperature processes due to the unique properties such as increased yield strength, low ductility, and differences in tensile and compressive strengths that result from microstructural features due to the CS process. Here we report the results of plate impact experiments applied to CS deposits of tantalum (Ta), niobium (Nb), and a tantalum- niobium blend (TaNb). These methods allowed for definition of the Hugoniot for each material type and allowed for assessment of the Hugoniot Elastic Limit (HEL). Scanning electron microscopy was used on recovered samples to characterize the fracture mechanism during spallation.

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Researchers at Sandia National Laboratories have recently conducted a series of experiments on novel cold spray deposited materials to understand dynamic material properties at high strain rates.

Dynamic compression of materials can induce a variety of microstructural changes. As thermally-sprayed materials have highly complex microstructures, the expected pressure at which changes occur cannot be predicted a priori. In addition, typical in-situ measurements such as velocimetry are unable to adequately diagnose microstructural changes such as failure or pore collapse. Quasi-isentropic compression experiments with sample recovery were conducted to examine microstructural changes in thermally sprayed tantalum and tantalum-niobium blends up to 8 GPa pressure. Spall fracture was observed in all tests, and post-shot pore volume decreased relative to the initial state. The blended material exhibited larger spall planes with fracture occurring at interphase boundaries. An estimate of the pressure at which pore collapse is complete was determined to be ~26 GPa for pure tantalum and ~19 GPa for the tantalumniobium blend under these loading conditions.

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The ability to surface engineer structures or components using coatings made by the thermal spray processes is very common practice and offers great design flexibility with traditional structure metallic substrates (e.g., Al, Steel, Ti). However, the joining of high melting temperature materials to a polymeric substrate presents a problem due to the melt deposition coating formation mechanism locally subjecting the polymer substrate to temperatures exceeding the limits of the polymer. Thus, it was desired to modify the surface of a polymer so that a thin metallic film could be robustly bonded to the polymer and act as a heat sink for impinging molten droplets from a thermal spray process and allow a thick film coating to be built upon the polymer.

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