Publication alert
Our latest work on "A meshless computational framework for studying cold spray additive manufacturing including large numbers of powder particles with diverse characteristics" has been published in Nature Scientific Reports.
Compared to fusion-based additive manufacturing technologies, cold spray additive manufacturing (CSAM) offers distinct advantages in the fabrication of components while avoiding some melting/solidification-related issues such as phase transformation and oxidation. It involves intricate processes that pose significant challenges for numerical studies, particularly for simulating the entire process at a large scale.
In this work, we developed an improved meshless computation framework to model and investigate CSAM with diverse particle characteristics. A modified material model is incorporated to consider the strain rate sensitivity effects, which provides more accurate predictions of particle deformations compared to conventional Johnson-Cook models. Our approach significantly enhances computational scalability, enabling the simulation of approximately ten million SPH particles. This capability enables a detailed comparative study of the bonding mechanisms of particles with different sizes, revealing a four-stage coating process. Moreover, the effects of powder morphology on the bonding process and pore formation were thoroughly investigated, providing valuable insights for practical engineering applications. This study marks the first attempt to reproduce the entire process of CSAM, including large numbers of powder particles with diverse characteristics.
Check out the full paper for external page more details.
