Research progress and prospect of numerical simulation of deposit morphology control in solid-state cold spray additive manufacturing
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摘要: 冷喷涂固态增材制造技术因其沉积效率高、喷涂速度快、热影响小等优点，逐渐成为各国研究热点. 但由于沉积原理与目前发展较为成熟的传统激光增材制造技术具有显著不同，沉积体的形貌控制成为了限制其应用的难点. 基于现有的冷喷涂条件对沉积体形貌影响的研究结果，结果表明，数值模拟成为了形貌预测与控制的主要方法. 因此，综述了冷喷涂沉积体形貌预测的不同数值模拟方法，总结了各个方法的特点，最后对冷喷涂沉积体形貌模拟的现存难题及未来发展方向进行了展望.Abstract: Solid-state cold spray additive manufacturing (CSAM) technology has become increasing hot in research among many countries for its high deposition efficiency, fast deposition speed and low thermal effect. Since the deposition method of CSAM is quite different with that of the traditionally laser additive manufacturing , the control of the deposit morphology has become a major task in the application of the technology. Based on the current conditions, numerical simulation methods have been carried out to study the effect of cold spray on the morphology of deposition. The results show that numercial simulation is a good way to predict and control the deposit morphology. In this paper, various simulation methods were proposed to predict the depositon morphology of CSAM and the characteristic of each method were summarized. Finally, challenges at present and prospect of the simulation of CSAM deposit morphology were proposed.
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图 1 喷涂时瞬时沉积体形貌与温度分布[30]
Figure 1. Transient deposits profile and temperature distribution. (a) t = 3 s; (b) t = 6 s; (c) t = 8 s; (d) t = 9.6 s; (e) t = 14.6 s; (f) t = 33 s
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图 3 凸起表面基体沉积[39]
Figure 3. Deposits on substrate convex angle. (a) deposits on substrate with 30° corner; (b) comparison of deposits profile under different spraying strategies
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图 5 不同喷涂条件对沉积体形貌的影响[42]
Figure 5. Influence of different spraying conditions on the profile of deposit. (a) spraying angle; (b) traversing speed; (c) standoff distance
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图 6 不同喷涂条件下沉积体实际形貌与人工神经网络法及高斯法模拟形貌对比[42]
Figure 6. Comparison of deposits profile between ANN method and Gaussian Model under different spraying conditions. (a) sample 37; (b) sample 39
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图 7 不同喷涂角度下单点沉积体形貌轮廓试验结果与ANN方法模拟结果对比[45]
Figure 7. Profile comparison of single spot spraying deposit between experiments and ANN method at different spray angles. (a) spraying angle of 90°; (b) spraying angle of 80°; (c) spraying angle of 70°; (d) spraying angle of 60°
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图 8 不同喷枪移动速度单道沉积体形貌轮廓实验结果与ANN方法模拟结果对比[45]
Figure 8. Comparison of deposits profile between experiments and ANN method under different traversing speed. (a) traversing speed 300 mm/s; (b) traversing speed 200 mm/s; (c) traversing speed 150 mm/s; (d) traversing speed 100 mm/s; (e) traversing speed 50 mm/s; (f) deposits thickness
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图 9 不同喷涂角度沉积体形貌3D模拟[45]
Figure 9. 3D simulation of single spot deposit profile at different spray angles. (a) θ = 90°; (b) θ = 80°; (c) θ = 70°; (d) θ = 60°
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图 10 沉积形貌预测流程[18]
Figure 10. Schematic diagram of depositing process. (a) planar creation of rays and intersection; (b) planar creation of cylinders; (c) planar single deposit profile; (d) non-planar creation of rays and intersection; (e) non-planar creation of cylinders; (f) non-planar single deposit profile
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图 11 复杂曲面冷喷涂[18]
Figure 11. Complex surface spraying. (a) discrete single deposit profile while overlapping; (b) continuous single deposit profile on flat surface; (c) continuous single deposit profile on curved surface; (d) continuous single deposit profile on complex stair surface
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图 12 阶梯状连续冷喷涂[18]
Figure 12. Continuous deposition on stair-like substrate with shadow effect. (a) actual profile; (b) simulation profile
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图 14 阴影遮挡效应的实现[54]
Figure 14. Shadow effect. (a) geometric shape of the substrate; (b) schematic diagram of spraying; (c) comparison of profile after 20 passes; (d) cross-sectional view after 20 passes; (e) side view of deposits; (f) profile of deposits
表 1 不同方法特点对比
Table 1 Comparison of characteristics of different methods
特点 高斯法 ANN TST 克林科夫法 3D — — √ — 物理模型 √ — — √ 复杂曲面喷涂 — — √ — 形貌演变 — — √ √ 数据支撑 √ √ — — 试验验证 — √ √ √ 非空间对称颗粒分布 — — — — 
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