Theoretical prediction of residual stresses induced by cold spray with experimental validation

Dibakor Boruah, Xiang Zhang, Matthew Doré

Research output: Contribution to journalArticle

2 Citations (Scopus)
44 Downloads (Pure)

Abstract

Purpose: The purpose of this paper is to develop a simple analytical model for predicting the through-thickness distribution of residual stresses in a cold spray (CS) deposit-substrate assembly. Design/methodology/approach: Layer-by-layer build-up of residual stresses induced by both the peening dominant and thermal mismatch dominant CS processes, taking into account the force and moment equilibrium requirements. The proposed model has been validated with the neutron diffraction measurements, taken from the published literature for different combinations of deposit-substrate assemblies comprising Cu, Mg, Ti, Al and Al alloys. Findings: Through a parametric study, the influence of geometrical variables (number of layers, substrate height and individual layer height) on the through-thickness residual stress distribution and magnitude are elucidated. Both the number of deposited layers and substrate height affect residual stress magnitude, whereas the individual layer height has little effect. A good agreement has been achieved between the experimentally measured stress distributions and predictions by the proposed model. Originality/value: The proposed model provides a more thorough explanation of residual stress development mechanisms by the CS process along with mathematical representation. Comparing to existing analytical and finite element methods, it provides a quicker estimation of the residual stress distribution and magnitude. This paper provides comparisons and contrast of the two different residual stress mechanisms: the peening dominant and the thermal mismatch dominant. The proposed model allows parametric studies of geometric variables, and can potentially contribute to CS process optimisation aiming at residual stress control.

Original languageEnglish
Pages (from-to)599-616
Number of pages18
JournalMultidiscipline Modeling in Materials and Structures
Volume15
Issue number3
Early online date5 Apr 2019
DOIs
Publication statusPublished - 7 May 2019

Fingerprint

Experimental Validation
Spray
Residual Stress
Residual stresses
Prediction
Stress Distribution
Substrate
Stress concentration
Shot peening
Substrates
Deposits
Neutron diffraction
Process Optimization
Parametric Model
Neutron
Analytical Model
Design Methodology
Diffraction
Analytical models
Finite Element Method

Bibliographical note

Copyright © and Moral Rights are retained by the author(s) and/ or other copyright owners. A copy can be downloaded for personal non-commercial research or study, without prior permission or charge. This item cannot be reproduced or quoted extensively from without first obtaining permission in writing from the copyright holder(s). The content must not be changed in any way or sold commercially in any format or medium without the formal permission of the copyright holders.

Funder

Lloyd's Register Foundation

Keywords

  • Residual Stress
  • Analytical Modelling
  • Cold Spray
  • Additive Manufacturing
  • Coatings
  • Repairs
  • Thermal spray
  • Analytical prediction
  • Aluminium alloy
  • Magnesium
  • Titanium
  • Neutron diffraction

Cite this

Theoretical prediction of residual stresses induced by cold spray with experimental validation. / Boruah, Dibakor; Zhang, Xiang; Doré, Matthew.

In: Multidiscipline Modeling in Materials and Structures, Vol. 15, No. 3, 07.05.2019, p. 599-616.

Research output: Contribution to journalArticle

@article{a482ef8b8a6842eebe7e9c18b04d100a,
title = "Theoretical prediction of residual stresses induced by cold spray with experimental validation",
abstract = "Purpose: The purpose of this paper is to develop a simple analytical model for predicting the through-thickness distribution of residual stresses in a cold spray (CS) deposit-substrate assembly. Design/methodology/approach: Layer-by-layer build-up of residual stresses induced by both the peening dominant and thermal mismatch dominant CS processes, taking into account the force and moment equilibrium requirements. The proposed model has been validated with the neutron diffraction measurements, taken from the published literature for different combinations of deposit-substrate assemblies comprising Cu, Mg, Ti, Al and Al alloys. Findings: Through a parametric study, the influence of geometrical variables (number of layers, substrate height and individual layer height) on the through-thickness residual stress distribution and magnitude are elucidated. Both the number of deposited layers and substrate height affect residual stress magnitude, whereas the individual layer height has little effect. A good agreement has been achieved between the experimentally measured stress distributions and predictions by the proposed model. Originality/value: The proposed model provides a more thorough explanation of residual stress development mechanisms by the CS process along with mathematical representation. Comparing to existing analytical and finite element methods, it provides a quicker estimation of the residual stress distribution and magnitude. This paper provides comparisons and contrast of the two different residual stress mechanisms: the peening dominant and the thermal mismatch dominant. The proposed model allows parametric studies of geometric variables, and can potentially contribute to CS process optimisation aiming at residual stress control.",
keywords = "Residual Stress, Analytical Modelling, Cold Spray, Additive Manufacturing, Coatings, Repairs, Thermal spray, Analytical prediction, Aluminium alloy, Magnesium, Titanium, Neutron diffraction",
author = "Dibakor Boruah and Xiang Zhang and Matthew Dor{\'e}",
note = "Copyright {\circledC} and Moral Rights are retained by the author(s) and/ or other copyright owners. A copy can be downloaded for personal non-commercial research or study, without prior permission or charge. This item cannot be reproduced or quoted extensively from without first obtaining permission in writing from the copyright holder(s). The content must not be changed in any way or sold commercially in any format or medium without the formal permission of the copyright holders.",
year = "2019",
month = "5",
day = "7",
doi = "10.1108/MMMS-08-2018-0150",
language = "English",
volume = "15",
pages = "599--616",
journal = "Multidiscipline Modeling in Materials and Structures",
issn = "1573-6105",
publisher = "Emerald",
number = "3",

}

TY - JOUR

T1 - Theoretical prediction of residual stresses induced by cold spray with experimental validation

AU - Boruah, Dibakor

AU - Zhang, Xiang

AU - Doré, Matthew

N1 - Copyright © and Moral Rights are retained by the author(s) and/ or other copyright owners. A copy can be downloaded for personal non-commercial research or study, without prior permission or charge. This item cannot be reproduced or quoted extensively from without first obtaining permission in writing from the copyright holder(s). The content must not be changed in any way or sold commercially in any format or medium without the formal permission of the copyright holders.

PY - 2019/5/7

Y1 - 2019/5/7

N2 - Purpose: The purpose of this paper is to develop a simple analytical model for predicting the through-thickness distribution of residual stresses in a cold spray (CS) deposit-substrate assembly. Design/methodology/approach: Layer-by-layer build-up of residual stresses induced by both the peening dominant and thermal mismatch dominant CS processes, taking into account the force and moment equilibrium requirements. The proposed model has been validated with the neutron diffraction measurements, taken from the published literature for different combinations of deposit-substrate assemblies comprising Cu, Mg, Ti, Al and Al alloys. Findings: Through a parametric study, the influence of geometrical variables (number of layers, substrate height and individual layer height) on the through-thickness residual stress distribution and magnitude are elucidated. Both the number of deposited layers and substrate height affect residual stress magnitude, whereas the individual layer height has little effect. A good agreement has been achieved between the experimentally measured stress distributions and predictions by the proposed model. Originality/value: The proposed model provides a more thorough explanation of residual stress development mechanisms by the CS process along with mathematical representation. Comparing to existing analytical and finite element methods, it provides a quicker estimation of the residual stress distribution and magnitude. This paper provides comparisons and contrast of the two different residual stress mechanisms: the peening dominant and the thermal mismatch dominant. The proposed model allows parametric studies of geometric variables, and can potentially contribute to CS process optimisation aiming at residual stress control.

AB - Purpose: The purpose of this paper is to develop a simple analytical model for predicting the through-thickness distribution of residual stresses in a cold spray (CS) deposit-substrate assembly. Design/methodology/approach: Layer-by-layer build-up of residual stresses induced by both the peening dominant and thermal mismatch dominant CS processes, taking into account the force and moment equilibrium requirements. The proposed model has been validated with the neutron diffraction measurements, taken from the published literature for different combinations of deposit-substrate assemblies comprising Cu, Mg, Ti, Al and Al alloys. Findings: Through a parametric study, the influence of geometrical variables (number of layers, substrate height and individual layer height) on the through-thickness residual stress distribution and magnitude are elucidated. Both the number of deposited layers and substrate height affect residual stress magnitude, whereas the individual layer height has little effect. A good agreement has been achieved between the experimentally measured stress distributions and predictions by the proposed model. Originality/value: The proposed model provides a more thorough explanation of residual stress development mechanisms by the CS process along with mathematical representation. Comparing to existing analytical and finite element methods, it provides a quicker estimation of the residual stress distribution and magnitude. This paper provides comparisons and contrast of the two different residual stress mechanisms: the peening dominant and the thermal mismatch dominant. The proposed model allows parametric studies of geometric variables, and can potentially contribute to CS process optimisation aiming at residual stress control.

KW - Residual Stress

KW - Analytical Modelling

KW - Cold Spray

KW - Additive Manufacturing

KW - Coatings

KW - Repairs

KW - Thermal spray

KW - Analytical prediction

KW - Aluminium alloy

KW - Magnesium

KW - Titanium

KW - Neutron diffraction

UR - http://www.scopus.com/inward/record.url?scp=85063890499&partnerID=8YFLogxK

U2 - 10.1108/MMMS-08-2018-0150

DO - 10.1108/MMMS-08-2018-0150

M3 - Article

VL - 15

SP - 599

EP - 616

JO - Multidiscipline Modeling in Materials and Structures

JF - Multidiscipline Modeling in Materials and Structures

SN - 1573-6105

IS - 3

ER -