Three-Dimensional Numerical Modeling of Cold Spray Process: Effect of Nozzle Shape on Particle Velocity

Cold gas dynamic spraying is a high rate material deposition process and capable of depositing a variety of materials without extensive heating. In which fine powder particles are accelerated in a supersonic jet and impact on the substrate surface, deform at temperature below their melting point and rapidly building up a layer of coating. Since the velocity of the particle impact on the substrate surface plays a vital role in deposition efficiency, a three dimensional numerical model is developed to study the in-flight behavior of particles and the interaction between the shock wave and the particles in a supersonic jet impinging onto the substrate. In order to accurately capture the turbulent characteristics, the Reynolds Stress Model (RSM) is used. The effect of main gas temperature in two common, commercial nozzles (PLASMA GIKEN PCS-305L and PCS-305L) is studied. Predicted and measured particle velocities are compared. Predicted results are comparable with measurements.