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7399 |
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Wednesday, May 04, 2022, Hall G1 10:50 AM Modeling & Simulation I |
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Numerical evaluation of thermo-mechanical residual stress induced during cold spray additive manufacturing |
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Amir Ardeshiri Lordejani* / Politecnico di Milano, Italy Sara Bagherifard / Politecnico di Milano, Italy Mario Guagliano/ Politecnico di Milano, Italy |
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Cold Spray has recently emerged as an additive manufacturing process. However, there are still issues that limit the buildability of freeform structures using cold spray. The deposition process is based on high velocity impact of relatively heated particles to the surface of the substrate. The peening effect of the impact will result in induction of a compressive residual stress in the impact region. In addition, the thermal mismatch between the substrate and the adhered particle will in turn, introduce an additional share of residual stress. Application of Cold Spray as an additive manufacturing method implies creation of relatively large areas of thick coating. This will require consecutive deposition of numerous layers, the quality and integrity of which depend on the careful selection of both materials, and process parameters. To avoid occurrence of flaws such as warping and premature delamination, predicting the evolution of induced residual stress during the deposition process is of utmost importance. In this study, a numerical framework is proposed to evaluate the effect of different process parameters on the induced residual stress during cold spray additive manufacturing. For this purpose, a series of finite element models are created and analyzed in ABAQUS software, which can estimate the individual and accumulative effect of various parameters on the final state of residual stress in large scales. The numerical results, supported by existing and new experimental observations, confirm the necessity of careful parameter selection for successful application of cold spray as an additive manufacturing method. Keywords: Cold Spray, Additive Manufacturing, Finite Element Simulation, Process Parameter, Residual Stress. |