ArticleProceedings of the National Academy of Sciences of the United States of America2025
Microparticle impact-induced bond strength in metals peaks with velocity.
Article in Proceedings of the National Academy of Sciences of the United States of America, 2025. The graph could read no effect estimate from its abstract, so it casts no vote on the map. Not yet cited in PubMed.
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Abstract
Supersonic impact of metallic microparticles onto metallic substrates generates extreme interfacial deformation and high contact pressures, enabling solid-state metallic bonding. Although higher impact velocities are generally believed to improve bond quality and mechanical properties in materials formed by supersonic impact deposition, here we report a peak in bond strength for single microparticle impact bonding, followed by a decline at higher impact velocities. Our in situ micromechanical measurements of interfacial strength for Al microparticles bonded to Al substrates reveal a three-fold increase from the critical bonding velocity (800 m/s) to a peak strength around 1,060 m/s. Interestingly, further increase in impact velocity results in a rapid decline in local interfacial strength. The decline continues up to the highest velocity studied, 1,337 m/s, which is well below the threshold required to induce melting or erosion. We show that a mechanistic transition from material strengthening to intensified elastic recovery is responsible for the peak strength in impact-induced bonding, with evidence linking the intensified elastic recovery to adiabatic softening at high impact velocities. Beyond 1,000 m/s for Al, interfacial damage induced by the intensified elastic recovery offsets the strength gain from higher impact velocities, resulting in a net decline in interfacial strength. This mechanistic understanding shall offer insights into the optimal design of processes that rely on impact bonding.
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