Transient Thermal Evolution during Deposition of Cold-sprayed Coatings

Knowledge of the thermal interaction between the substrate and the deposited particles during the cold spray coating fabrication process can shed light on coating formation and bonding mechanisms that occur. In this study, a mathematical model, which was based on the differential quadrature method (DQM), was used to solve the hyperbolic (non-Fourier) heat conduction problem to predict the transient thermal evolution within the substrate and the coating during the impact of a single particle. The mathematical model was coupled to a semi-empirical analytical model to take into account the convective heat transfer due to the impingement of the moving cold spray air jet. In addition, a three-dimensional finite element model was developed to simulate the thermal and dynamic behavior of a single particle upon impact. The results of the mathematical model for the transient thermal evolution within the substrate and the coating were compared to the results of the numerical model and good agreement was found. It was concluded that the proposed analytical-numerical model could be further expanded to simulate multiple particle impacts to predict the transient temperature in the coating during the cold spray deposition process with application to additive manufacturing.