Unraveling the Mesoscale Evolution of Microstructure during Supersonic Impact of Aluminum Powder Particles

A critical challenge in the predictive capability of materials deformation behavior under extreme environments is the availability of computational methods to model the microstructural evolution at the mesoscale. The capability of the recently-developed quasi-coarse-grained dynamics (QCGD) method to model mesoscale behavior is demonstrated for the phenomenon of supersonic impact of 20 µm sized Al particles on to an Al substrate at various impact velocities and over time and length scales relevant to cold spray deposition. The QCGD simulations are able to model the kinetics related to heat generation and dissipation, and the pressure evolution and propagation, during single particle impact over the time and length scales that are important experimentally. These simulations are able to unravel the roles of particle and substrate deformation behavior that lead to an outward/upward flow of both the particle and the substrate, which is a likely precursor for the experimentally observed jetting and bonding of the particles during cold spray impact.