Nozzle Design Influence on the Supersonic Particle Deposition Process

by Victor Champagne, Dennis Helfritch, Phillip Leyman, Robert Lempicki and Scott Grendahl U.S. Army Research Laboratory Aberdeen Proving Ground, MD presented at the Cold Spray 2004 Conference
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Purpose
To improve cold spray deposition through the investigation of: Nozzle geometry Accelerating gas characteristics Particle characteristics

Outline
1. Calculate the gas flow and temperature in the nozzle 2. Calculate particle velocity and temperature through the nozzle 3. Calculate penetration depth and particle/substrate mixing 4. Calculate the deposition efficiency 5. Compare with experiment
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Apply Gasdynamic Analysis to Simple Nozzle Geometry

rt L re

The gas obeys the perfect gas law There is no friction impeding the gas flow The gas flow is adiabatic No shocks or discontinuities Flow is one-dimensional Particles do not influence gas conditions
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Particle Motion/Deposition
Using the gas flow already calculated, employ solid rocket nozzle particle drag and heat transfer relationships* to calculate particle conditions. Particles are assumed to be spherical. Particle initial temperature = 293 degree K. Use empirical relationships between particle velocity and particle/substrate material characteristics to calculate deposition effects.
*D. Carlson and R. Hoglund: Particle Drag and Heat Transfer in Rocket Nozzles, AIAA Journal, 1964, 2(11), pp. 1980 -1984.

Conditions of Calculations
Unless otherwise stated, all calculations are carried out for the following conditions: Area ratio = 4, Length = 0.1m Nitrogen accelerating gas 2.76 MPa, 673 degree K stagnation conditions Copper particles Mass mean diameter 20 microns Log-normal distribution, SD = 1.5
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Typical Calculation
Velocity & Temperature, m/s & degree K 1000 800 600 400 200 0 0.00

0.02

0.04
particle temp gas temp

0.06

0.08

0.10

Nozzle Axis, meters

particle velocity gas velocity nozzle throat
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Particle Exit Conditions as a Function of Diameter and Accelerating Gas

Particle Velocity, m/s
2500 2000 1500 1000 500 0 0 20 40 60 80 500 400 300 200 100 0 100 Particle Temp, deg. K

Particle Diameter, microns

Velocity, He Velocity, N2 Temperature, He Temperature, N2
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Effect of Nozzle Length on Particle Velocity

700 Particle Exit Velocity, m/s 650 600 550 A/A* = 12.25, calculated 500 450 400 5 10 15 20 Nozzle Length, cm 25 30
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A/A* = 4.0, calculated A/A* = 12.25, measured A/A* = 4.0, measured

Deposition Calculations Particle/Substrate

Empirical micrometeorite penetration into spacecraft*

(4x10 )E Volume =
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Substituting 1/2mV2 for energy, with volume = 2rr2

V = 7.5x10 4

0.5

*R.J. Eichelberger and J.W. Gehring: Effects of Meteoroid Impacts on Space Vehicles, ARS J., 1963, 32(10), p. 1583.

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Copper Deposited on Aluminum

Particle/substrate equation predicts a velocity of 500 m/s needed for full penetration. Photograph below shows this condition.

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Deposition Calculations Particle/Particle

The empirical relationship for the critical velocity is given by Assadi* as: Critical Velocity = 667 - 14 + 0.08Tm + 0.1 - 0.4Te = particle density = particle UTS Tm = particle melting point Te = particle exit temperature

All particles smaller than that exiting with the critical velocity will deposit
*H. Assadi, et al: Bonding Mechanism in Cold Gas Spraying, Acta Materialia, 2003, 51, pp. 4379 4394.
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Deposition Efficiency Calculation

1. Calculate table of particle exit velocities and temperatures vs. particle diameter. 2. Calculate critical velocities based on the particle exit temperatures. 3. Find the critical particle size that has an exit velocity equal to the critical velocity. 4. Integrate the log normal particle size distribution from the critical diameter to 1/infinity.
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Critical Particle Diameter Particle Exit Conditions

Exit Velocity, m/s & Temp, C 1000
velocity

800 600 400 200 0 0 20

temperature critical velocity

40

60

80

100

Particle Diameter
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Effect of Particle Diameter on Deposition Efficiency

100 Deposition Efficiency
Nitrogen Helium

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1 0 20 40 60 80 Particle Mass Mean Diameter, microns

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Effect of Nozzle Area Ratio on Deposition Efficiency

100 Deposition Efficiency 80 60 40 20 0 0 5 10 Nozzle Area Ratio
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6 micron MMD 10 micron MMD 30 micron MMD

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Effect of Nozzle Area Ratio on Deposition Efficiency - Helium

100 Deposition Efficiency 80 60 40 20 0 0 5 10 Nozzle Area Ratio 15 20
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10 micron 30 micron

Effect of Nozzle Length on Deposition Efficiency

70 Deposition Efficiency 60 50 40 30 20 10 0 5 10 15 20 25 30
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Nozzle Length, cm

Conclusions
Particle exit conditions are principally determined by nozzle length and particle diameter. Particle/surface interaction can be characterized by particle velocity and surface hardness. Particle velocity and deposition efficiency are relatively insensitive to nozzle area ratio. Large improvements to deposition efficiency are possible through the use of smaller particles and longer nozzles.

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Parameters for Calculation

0.1 0.001 0.05 673 400 2758000 28 8314 1.4 0.9 0.001 Fn(M0) 0.001 0.002 0 0.03 0.1 4.00 1.00E-05 9 7.85E-11 4.71E-12 2.00E-05 293 390 0.03 1084 345 12.00 1.5 1 0.3180 M0 delM, M<1 delM, M>1 T0 degK P0 psia P0 pascal MW R gamma Vp0/Vg0 throat radius m y0 y1 y2 x0 x1 x2 Ae/A* reference diameter m material density g/cc particle area m^2 particle mass kg viscosity kg/m-sec Tp0 K particle Cp J/kg-K gas cond. Kg-m/s^3-K melting Point, C particle UTS, Mpa critical diameter std dev ERF sign ERF argument microns 1 3 6 10 30 60 100 Vp, m/s 890 762 670 602 412 299 230 Tp, C -11 44 153 208 113 58 39 Vc, m/s 667 645 601 579 617 639 647 Tp critical 0 0 0 199 0 0 critical dia 0 0 0 12 0 0

Exit Velocity, m/s & Temp, C

10 MMD 67.35 Deposition Efficiency

y0 x0

Particle Exit Conditions 1000

velocity

800 600 400 200 0 0 20

temperature critical velocity

y1 same N2-He x1

.03N2-.15He

40

60

80

100

Particle Diameter

y2 x2

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Effect of Feeder Gas Mixing

600 Nozzle Chamber Gas Temperature, C 500 400 300 200 100 0 0 0.1 0.2 0.3 0.4
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Hopper Flow/Main Flow