This study presents a finite element approach of a numerical model to investigate the profile of the deformed sprayed particles and the compressive residual stresses analysis at the interfacial zone of particle and substrate impact using cold gas dynamic spray (CGDS). The Lagrangian approach was used to analyze, in details, the material deformation behavior during impact, contact problems of single-particle impact process and the outputs of equivalent plastic strain and temperature to achieve a qualitative understanding of cold gas dynamic spray contact process of cold sprayed particle on the substrate. The evolution of residual compressive stresses during impact was also analyzed for multiple-particles impact process using the Lagrangian approach. It can be observed that the compressive residual stresses increase by increasing the preheating temperature and particle initial impact velocity.

Finite Element Analysis was carried out to describe the effect of frictional boundary conditions and percentage reduction on deformation modelling (forward extrusion) of Aluminum AA6063 alloy. Curved die profiles of regular polygons (square, hexagonal, heptagonal, and octagonal) were designed using MATLAB R2009b and Autodesk Inventor 2013 to generate the coordinate and the solid CAD model of the die profile respectively form a circular billet. The numerical analysis was performed using DeformTM-3D commercial package with frictional boundary conditions of 0.38 and 0.75 representing the wet and dry condition and varying the percentage reduction of 50%, 70%, and 90%. The results of the temperature distribution, effective stress, effective strain, and strain rate were reported. As the percentage area reduction increases, the extrusion pressure also increases with an increasing frictional condition, and die length. Also, extrusion pressure decreases when the side of the polygon increases from square-shaped section follow by hexagonal shaped-section and least in octagonal shaped-section for both friction factors and percentage area reductions. For a given percentage reduction and cross-sectional area, there is no distinct difference between the predictive loads for the shaped-polygons. When the result of this analysis is compared with the experimental results from the literature, it is evident that DeformTM-3D is an effective tool for finite element analysis of non-isothermal deformation processes.

In the present research work using a backward cup extrusion (BCE) die profile, different lubricating conditions on aluminum alloy AA6063 have been experimentally and numerically investigated to predict the extrusion load. It was obvious that due to an increase in applications of the extrusion process, many researchers have worked on the extrusion process using different methods to achieve their aims. This experiment was conducted with three different lubricants namely: Castor oil, Palm Oil and tropical coconut oil; as well as without lubricants. Different lubricating conditions were employed of varying strain rates ranges from 1.5×10-3s-1, 2.0×10-3s-1, 2.5×10-3s-1, and 3.0×10-3s-1; Numerical analysis and simulation for dry and lubricated conditions during extrusion load were also performed using DEFORM 3D software. The results show that prediction extrusion load increases with increasing strain rates. The maximum extrusion load was found to be higher for extrusion without lubricants. In all cases of strain rate, palm oil showed a lower extrusion load compared to the other lubricants. Castor oil indicated the highest extrusion load when the experiment is carried out using lubrication. There was a consistent agreement between the result gotten from the experiment and simulation result of the extrusion load-strike curve.