Finite element modelling and simulation of the multiscale crystalline structure of aluminium deposit produced by helium cold spray additive manufacturing
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Date
2025-08-26
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Abstract
This study addresses an experimental analysis with a multiscale modelling of a pure
Aluminium deposit produced by helium cold spraying. The grain morphology and the
crystallographic texture of the deposit revealed a significant grain refinement along with a
formation of strong metallurgical bonding. Complementing the experiments, a two-part
multiscale modelling framework is developed, integrating a simulation of the particle upon
impact and a crystal plasticity finite element model for analysing the consolidation and
deformation mechanisms across multiple scales. Using Johnson-Cook equations and
coupled Eulerian-Lagrangian approach, the particle impact model effectively captures
high velocity impact behaviour, deformation mechanisms, and thermal interactions at the
particle-substrate interface. The influence of intergranular interactions and phase
heterogeneities on the overall mechanical response, at the mesoscale level, is investigated.
The crystal plasticity-based approach can simulate the behaviour of individual grains within
a representative volume element (RVE), with a prediction of the anisotropic mechanical
properties and stress-strain relationships between various grains. The results pave the way
for a better understanding of the microstructural evolution and mechanical behaviour of
Aluminium deposits produced by helium cold spraying.
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Keywords
Cold Spray, Plasticity Simulation, Crystal, Additive Manufacturing, Aluminium, Modelling, Microstructure
Subjects based on RSWK
Kaltspritzen, Mikrostruktur, Finite-Elemente-Methode, Rapid Prototyping <Fertigung>, Simulation, Aluminium, Kristallstrukturanalyse