Numerical simulation of solid particles impinging on a substrate at high speed: Influence of the particle temperature

Additive manufacturing processes have been used to produce or repair components in different industry sectors like aerospace, automotive, and biomedical. In these processes, a part can be built by either melted particles as in selective laser melting (SLM) or solid-state particles as in the cold spray process. Cold spray has gained significant attention due to its potential for high deposition rate and nearly zero oxidation. However, the main concern associated with using the cold spray is the level of porosity in as-fabricated samples which can alter their properties. These pores are mostly found in the regions where adiabatic shear instability does not occur. It is worth noting that the amount of deformation of the impacted solid particle plays an important role in reaching the shear instability. In this study, the influence of the temperature of the solid particles impinging on a substrate at high speed is investigated by using an elastic-plastic simulation approach. A particular attention is given to the size of adiabatic shear instability region as it correlates porosity level in as-fabricated samples.