Bonding mechanism from the impact of thermally sprayed solid particles

Power particles are mainly in solid state prior to impact on substrates from high velocity oxy-fuel (HVOF) thermal spraying. The bonding between particles and substrates is critical to ensure the quality of coating. Finite element analysis (FEA) models are developed to simulate the impingement process of solid particle impact on substrates. This numerical study examines the bonding mechanism between particles and substrates and establishes the critical particle impact parameters for bonding. Considering the morphology of particles, the shear-instability–based method is applied to all the particles, and the energy-based method is employed only for spherical particles. The particles are given the properties of widely used WC-Co powder for HVOF thermally sprayed coatings. The numerical results confirm that in the HVOF process, the kinetic energy of the particle prior to impact plays the most dominant role in particle stress localization and melting of the interfacial contact region. The critical impact parameters, such as particle velocity and temperature, are shown to be affected by the shape of particles, while higher impact velocity is required for highly nonspherical powder

Selection of the spraying technologies for over-coating of metal-stampings with thermo-plastics for use in direct-adhesion polymer metal hybrid load-bearing components

The suitability of various polymer-powder spraying technologies for coating of metal-stampings used in polymer metal hybrid (PMH) load-bearing automotive-component applications is considered. The suitability of the spraying technologies is assessed with respect to a need for metal-stamping surface preparation/treatment, their ability to deposit the polymeric material without significant material degradation, the ability to selectively overcoat the metal-stamping, the resulting magnitude of the polymer-to-metal adhesion strength, durability of the polymer/metal bond with respect to prolonged exposure to high-temperature/high-humidity and mechanical/thermal fatigue service conditions, and compatibility with the automotive body-in-white (BIW) manufacturing process chain. The analysis revealed that while each of the spraying technologies has some limitations, the cold-gas dynamic-spray process appears to be the leading candidate technology for the indicated applications

Energy and force analysis of Ti-6Al-4V linear friction welds for computational modeling input and validation data

The linear friction welding (LFW) process is finding increasing use as a manufacturing technology for the production of titanium alloy Ti-6Al-4V aerospace components. Computational models give an insight into the process, however, there is limited experimental data that can be used for either modeling inputs or validation. To address this problem, a design of experiments approach was used to investigate the influence of the LFW process inputs on various outputs for experimental Ti-6Al-4V welds. The finite element analysis software DEFORM was also used in conjunction with the experimental findings to investigate the heating of the workpieces. Key findings showed that the average interface force and coefficient of friction during each phase of the process were insensitive to the rubbing velocity; the coefficient of friction was not coulombic and varied between 0.3 and 1.3 depending on the process conditions; and the interface of the workpieces reached a temperature of approximately approximately 1273 K (1000 °C) at the end of phase 1. This work has enabled a greater insight into the underlying process physics and will aid future modeling investigations.EPSRC, Boeing Company, Welding Institut

Integration Concept of Injection, Forming and Foaming: A Practical Approach to Manufacture Hybrid Structures

Motivated by the concept of the integrative production systems, the hybrid process of polymer injection molding and sheet metal forming, known as polymer injection forming (PIF), has been introduced to manufacture sheet metal-polymer components in a single operation. Despite the wide potential application of this technology, its implementation in actual industrial production has been hindered due to several challenges; a thick layer of polymer where there is deep deformation, non-uniform deformation due to pressure loss and the opposite phenomena of shrinkage and springback. To mitigate these practical issues, the novel idea of integrating supercritical fluid (Sc.F.) technology with the PIF process is introduced in this work. As the proposed technology is a manufacturing innovation, with no available information in the literature correlating to this concept, two sets of experiments are designed to investigate the feasibility of this integration. In the first set, the effect of blank material and shot volume as design variables were investigated over a range of Sc.F. weight percentage. To improve the cell morphology in experiments with the low-strength sheet material, several other processing scenarios are explored in the second set of experiments. The results of this study clearly demonstrate the capabilities of this concept manufacturing process in terms of initiating the foaming process within the simultaneous injection/forming process, ensuring weight reduction (of up to 16%) and complete elimination of issues related to shrinkage

Measuring spatial pressure distribution from explosives buried in dry Leighton Buzzard sand

Direct measurement of the intense loading produced by the detonation of a buried explosive is an extremely difficult task. Historically, high-fidelity measurement techniques have not been sufficiently robust to capture the extremely high pressures associated with such events, and researchers have relied on ‘global’ measurements such as the average loading acting over a particular area of interest. Recently, a large-scale experimental approach to the direct measurement of the spatial and temporal variation in loading resulting from an explosive event has been developed, which utilises Hopkinson pressure bars (HPBs) inserted through holes in a large target plate such that their faces lie flush with the loaded face. This article presents results from ten experiments conducted at 1/4 scale, using 17 HPBs to measure the spatial pressure distribution from explosives buried in dry Leighton Buzzard sand, a commonly available sand used in many geotechnical applications. Localised pressure measurements are used in conjunction with high speed video to provide a detailed examination of the physical processes occurring at the loaded face, as well allowing quantification of these effects. Example pressure–time and impulse–time traces are provided in full to allow researchers to use this data for validation of numerical modelling approaches