Structure Formation of Low Pressure Cold Spray Coatings: A Powder Shock Consolidation Process Simulation

Numerical simulations of shock wave propagation through the  powder mixtures were performed to investigate the characteristics of deformation during Low Pressure Cold Spray (LPCS) of powder mixtures. The analysis of the spraying process is based on a micromechanics approach using multiple particle configurations. The material considered is elasto-viscoplastic with interparticle friction. Two-dimensional stress-strain analysis of discrete particles in various  packed arrangement was carried on the base of plane strain deformation model.  The finite element method using an explicit dynamic analysis procedure was used for the simulations. The final shape and temperature variations within the particles were analyzed. The results are believed to provide a better understanding of the LPCS shock consolidation features.