| Abstract: |
This study focuses on development of a finite element model to predict the mechanical response and to study the failure mechanism of cold-sprayed particulate-reinforced metal matrix composite coatings. In this regard, a set of representative volume elements was generated by employing the DIGIMAT software in order to replicate the approximate actual MMC geometry based on experimental data from the digital micrographs of cold-sprayed nickel-tungsten carbide MMC coatings. To that end, the volume fraction of the particles in the MMC, the mean free path between particles, and the average particle size were obtained from the available experimental data in order to generalize the geometry of the model. A three-dimensional finite element model was then developed in ABAQUS to simulate the uni-axial quasi-static tensile test on the representative volume element to predict the mechanical response and failure behavior of the MMC coatings. The mechanical response that was obtained from the numerical model was validated against the experimental data. It was shown that the increase in the interfacial area between the matrix and the reinforcing particles, as a result of the increase in volume fraction of inclusions, had a negligible effect on the numerically predicted mechanical properties of the cold-sprayed MMC coatings. It was concluded that the mechanical properties of the cold-sprayed coatings, e.g. tensile strength and failure strain of the cold-sprayed MMC coatings, were likely dependent on the plastic deformation of the metal matrix and the strength of the cohesive zone among the cold-sprayed metal splats. The outcome of the present study can shed light upon the influence of mechanisms and microstructure of cold-sprayed ceramic-metal coatings when exposed to industrial loading scenarios, and can guide future efforts to tailor and optimize material microstructures for improved wear performance of cold-sprayed MMC coatings.
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