Powder Consolidation Using Cold Spray : Process Modeling and Emerging Applications

This book firstpresents different approaches to modeling of the cold spray process with theaim of extending current understanding of its fundamental principles and thendescribes emerging applications of cold spray. In thecoverage of modeling, careful attention is devoted to the assessment ofcritical and erosion velocities. In order to reveal the phenomenologicalcharacteristics of interface bonding, severe, localized plastic deformation andmaterial jet formation are studied. Detailed consideration is also given to theeffect of macroscopic defects such as interparticle boundaries andsubsequent splat boundary cracking on the mechanical behavior of cold spraycoatings. The discussion of applications focuses in particular on therepair of damaged parts and additive manufacturing in various disciplinesfrom aerospace to biomedical engineering. Key aspects include a systematicstudy of defect shape and the ability of cold spray to fill the defect,examination of the fatigue behavior of coatings for structural applications,and a novel working window at subcritical conditions toobtain porous structures. This book is exceptional in scope, and its review offinite element modelling at different length scales sheds light on futuredesign and process improvement in emerging applications such as structuralrepair, metal additive manufacturing and metal foam design.