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Optimization of Cold Spray Deposition of High-Density Polyethylene Powders

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A Correction to this article was published on 19 December 2017

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Abstract

When a solid, ductile particle impacts a substrate at sufficient velocity, the resulting heat, pressure and plastic deformation can produce bonding between the particle and the substrate. The use of a cool supersonic gas flow to accelerate these solid particles is known as cold spray deposition. The cold spray process has been commercialized for some metallic materials, but further research is required to unlock the exciting potential material properties possible with polymeric particles. In this work, a combined computational and experimental study was employed to study the cold spray deposition of high-density polyethylene powders over a wide range of particle temperatures and impact velocities. Cold spray deposition of polyethylene powders was demonstrated across a range broad range of substrate materials including several different polymer substrates with different moduli, glass and aluminum. A material-dependent window of successful deposition was determined for each substrate as a function of particle temperature and impact velocity. Additionally, a study of deposition efficiency revealed the optimal process parameters for high-density polyethylene powder deposition which yielded a deposition efficiency close to 10% and provided insights into the physical mechanics responsible for bonding while highlighting paths toward future process improvements.

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Change history

  • 19 December 2017

    We regret that the original article contained an incorrect initial for the first listed author. The name should have been published to read: Trenton P. Bush.

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Acknowledgments

This research was accomplished through a cooperative research agreement with the US Army Research Laboratory, Contract: W911NF-15-2-0024, ‘Intelligent Processing of Materials by Design.’

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Authors and Affiliations

  1. Department of Mechanical and Industrial Engineering, University of Massachusetts, Amherst, MA, 01003, USA

    Trenton B. Bush, Zahra Khalkhali, David P. Schmidt & Jonathan P. Rothstein

  2. U.S. Army Research Laboratory, Weapons and Materials Research Directorate, Aberdeen Proving Ground, Aberdeen, MD, 21005, USA

    Victor Champagne

Authors
  1. Trenton B. Bush
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  2. Zahra Khalkhali
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  3. Victor Champagne
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  4. David P. Schmidt
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  5. Jonathan P. Rothstein
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Corresponding author

Correspondence to Jonathan P. Rothstein.

Additional information

A correction to this article is available online at https://doi.org/10.1007/s11666-017-0675-x.

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Bush, T.B., Khalkhali, Z., Champagne, V. et al. Optimization of Cold Spray Deposition of High-Density Polyethylene Powders. J Therm Spray Tech 26, 1548–1564 (2017). https://doi.org/10.1007/s11666-017-0627-5

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  • DOI: https://doi.org/10.1007/s11666-017-0627-5

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