Three-Dimensional Modelling of Cold Spray for Additive Manufacturing

Cold Spray can be used to form three-dimensional objects following layer-by-layer approach which is called Cold Gas Dynamic Manufacturing (CGDM). In this study, a three-dimensional simulation of CGDM for a high pressure nozzle with axial powder injection is investigated. During the manufacturing of a desirable object by CGDM, formation of sharp edges, stagnation points and corners are inevitable that can influence the trajectories of the particles. This leads to dispersion and lack of particle deposition in these areas that can eventually reduce the precision and efficiency of the spraying process. Three different objects of cylinder, frustum and hollow cylinder have been numerically simulated on a substrate to represent typical manufactured parts. Particle trajectories and impact conditions i.e. size, velocity and temperature distributions with and without these objects have been compared. The results of numerical modelling provided useful information for understanding the limitations and challenges associated with CGDM which can help us to improve the quality and precision of deposition.