Sains Malaysiana 51(2)(2022): 585-597

http://doi.org/10.17576/jsm-2022-5102-22

Impact Behaviour of Aluminum Particles upon Aluminum, Magnesium, and Titanium Substrates using High Pressure and Low-Pressure Cold Spray

(Kelakuan Kesan Zarah Aluminum ke atas Substrat Aluminum, Magnesium dan Titanium menggunakan Semburan Sejuk Tekanan Tinggi dan Tekanan Rendah)

ABREEZA MANAP^1,2*, SAVISHA MAHALINGAM¹, SITI NURUL AKMAL YUSOF², NURFANIZAN AFANDI² & HUDA ABDULLAH³

¹Institute of Sustainable Energy, Universiti Tenaga Nasional, Jalan IKRAM-UNITEN, 43000 Kajang, Selangor Darul Ehsan, Malaysia

²Department of Mechanical Engineering, Universiti Tenaga Nasional, Jalan IKRAM-UNITEN

43000 Kajang, Selangor Darul Ehsan, Malaysia

³Department of Electrical, Electronic and System Engineering, Faculty of Engineering and Built Environment, Universiti Kebangsaan Malaysia, 43600 UKM Bangi, Selangor Darul Ehsan, Malaysia

Received: 9 December 2020/Accepted: 18 July 2021

ABSTRACT

This study is focused on the impact and residual stress behaviour of aluminum component repair using aluminum powder via two different types of cold spray processes; high pressure cold spray (HPCS) and low-pressure cold spray (LPCS). It has been carried out via smoothed particle hydrodynamics simulations, comparing aluminum substrate with other lightweight materials such as titanium and magnesium. The obtained results have shown that the impact behaviour is influenced by velocity, porosity, deformation behaviour, flattening ratio, total energy and maximum temperature. The aluminum particles impacting on aluminum substrates using LPCS is slightly deformed, with the smallest flattening ratio leading to less pore formation between the particles. This has subsequently resulted in good coating quality. Furthermore, HPCS has contributed greatly to the deposition of particles on the heavier and harder substrate, such as titanium substrate. Thus, the overall result indicates that LPCS is better for repairing aluminum component compared to HPCS.

Keywords: Aluminum; high pressure cold spray; impact behaviour; low-pressure cold spray; residual stress

ABSTRAK

Kajian ini difokuskan pada impak dan tingkah laku tekanan sisa pembaikan komponen aluminum menggunakan serbuk aluminum melalui dua jenis proses penyemburan sejuk; semburan sejuk tekanan tinggi (HPCS) dan semburan sejuk tekanan rendah (LPCS). Ia telah dilakukan melalui simulasi hidrodinamik zarah halus, membandingkan substrat aluminum dengan bahan ringan lain seperti titanium dan magnesium. Hasil yang diperoleh menunjukkan bahawa tingkah laku impak dipengaruhi oleh halaju, keliangan, tingkah laku ubah bentuk, nisbah meratakan, jumlah tenaga dan suhu maksimum. Zarah aluminum yang mempengaruhi substrat aluminum menggunakan LPCS sedikit cacat, dengan nisbah meratakan terkecil yang menyebabkan pembentukan liang antara zarah-zarah tersebut. Ini kemudiannya menghasilkan kualiti salutan yang baik. Tambahan pula, HPCS telah banyak menyumbang kepada pemendapan zarah pada substrat yang lebih berat dan keras, seperti substrat titanium. Oleh itu, hasil keseluruhan menunjukkan bahawa LPCS lebih baik untuk memperbaiki komponen aluminum berbanding HPCS.

Kata kunci: Aluminum; semburan sejuk tekanan tinggi; semburan sejuk tekanan rendah; tekanan sisa; tingkah laku impak

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*Corresponding author; email: Abreeza@uniten.edu.my