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CFD Simulations of Feeder Tube Pressure Oscillations and Prediction of Clogging in Cold Spray Nozzles

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Abstract

Cold spray is an additive manufacturing method in which powder particles are accelerated through a supersonic nozzle and impinged into a nearby substrate. This method produces deposits with advantageous attributes, namely with low porosity and low residual stresses, which nearly match those of the bulk material. One challenge with cold spray is nozzle clogging, which occurs when particles bond to the inside of the nozzle, altering the cross-sectional area, increasing roughness on the nozzle inner surface, and causing a drop in the gas velocity, ultimately resulting in a lower quality deposit. Clogging puts certain combinations of materials and operational parameters out of practical reach. A CFD model of the cold spray nozzle is developed to study the flow of metal particles in the cold spray process, and we determine that the two-phase particle-laden flow from the feeder tube is inherently transient. CFD simulations demonstrate that pressure fluctuations in the particle feed system can cause the particles to disperse in the nozzle and ultimately lead to some particles bonding with the nozzle wall. The degree of clogging is found to be strongly dependent on the amplitude of these upstream pressure fluctuations and seemingly independent of the pressure oscillation frequency.

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Abbreviations

C D :

Coefficient of drag

c p :

Specific heat

d :

Diameter

E :

Energy

F :

Force

F1, F2 :

Empirical factors

g :

Gravity

J j :

Diffusion flux of species

k :

Thermal conductivity

P :

Pressure

Re:

Reynold’s number

R :

Individual gas constant

r :

Radial dimension

t :

Time

T i :

Particle impact temperature

T m :

Melting temperature

T R :

Reference temperature (293 K)

T :

Temperature

v :

Flow velocity

v crit :

Critical velocity

v impact :

Impact velocity

x :

Axial distance

μ :

Viscosity

ρ :

Density

σ TS :

Tensile strength

σ U :

Yield stress

τ :

Stress

τ r :

Drag force

eff:

Effective

p:

Particle

CVR:

Critical velocity ratio

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Acknowledgments

The authors acknowledge the contributions from the ARL, UTRC, and MGHPCC computing resources. Funding was provided from the Army Research Laboratory under Contract W911NF-15-2-0024.

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Correspondence to Piotr Liebersbach.

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Liebersbach, P., Foelsche, A., Champagne, V.K. et al. CFD Simulations of Feeder Tube Pressure Oscillations and Prediction of Clogging in Cold Spray Nozzles. J Therm Spray Tech 29, 400–412 (2020). https://doi.org/10.1007/s11666-020-00992-0

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Keywords

  • cold spray
  • computational fluid dynamics
  • clogging
  • feeder tube oscillations
  • particle dispersion
  • particle–wall collisions