3D Microstructure-based FE Simulation of Cold-sprayed Al-Al2O3 Composite Coatings under Indentation and Quasi-static Compression

This study developed microstructure-based finite element (FE) models to investigate the behavior of cold-sprayed aluminum-alumina (Al-Al₂O₃) metal matrix composites (MMCs) coatings subject to indentation and quasi-static compression. Based on microstructural features (i.e., particle weight fraction, particle size, and porosity) of the MMC coatings, representative volume elements (RVEs) were generated by using Digimat software and then imported into ABAQUS/Explicit. State-of-the-art in physics-based modelling approaches were incorporated into the model to account for particle cracking, interface debonding, and ductile failure in matrix to analyze and inform on the deformation and failure responses. The model was validated with experimental results for Al-18 wt.% Al₂O₃, Al-34 wt.% Al₂O₃, and Al-46 wt.% Al₂O₃ coatings under quasi-static compression by comparing the stress versus strain histories and observed failure mechanisms (e.g., matrix ductile failure). The results showed that the computational framework is able to capture the response of this cold-sprayed material system under compression and indentation, both qualitatively and quantitatively. This has implications for extending the model to materials design and under different types of loading (e.g., wear and fatigue).