Finite element simulation of material jet formation during cold spray deposition of Al and Ti alloys

Various physical/mechanical phenomena have been proposed so far to stand for the adhesion of particle to substrate in cold spray. However, there is a general agreement on material jet formation during high velocity impact of micro-sized particles. Using Eulerian framework, the present work proposes a simple but effective simulation of material jet formation and growth during cold spray of Al2024 and Ti6Al4V. General deformation, induced plastic strain, temperature rise in the particle and in particular in the material jet is presented and discussed. A critical discussion on critical velocity of the two materials is given. It is shown that an accurate knowledge of what occurs in the material jet could be an effective pathway to understand bonding phenomenon in cold spray.