Computational analysis of phenomenological gas flow behavior and particle kinematics during cold spray additive manufacturing

In this paper, the phenomenological behavior of gas flow and particles motion during cold spraying has been studied. Observations of particles behavior show two features: a uniform jet over a short distance ahead of the nozzle exit and then, a progressive dispersion. These behaviors are explained using a computational analysis based on a Direct Numerical Simulation (DNS) of the gas flow and the kinematic interactions with the particles. The DNS computation demonstrates that the gas stream starts to be unstable inside the nozzle with more turbulence as it moves towards the exit of the nozzle. The flow is self-oscillated along the flow direction and drives the motion of the Cu particles outside the nozzle. The zone of gas flow instability does correspond to the zone of experimental particle dispersion. Outside the nozzle, the particles form a straight jet over a certain distance that corresponds to the zone of the experimental uniform particles jet. Then, they are deviated and become more and more to be dispersed towards a very sparse jet along the flow direction. This phenomenon is explained by a Magnus lift force that deviates the particles trajectory when the gas flow becomes highly turbulent while developing a vorticity shedding.