Numerical Prediction of Critical Velocity and Spray Angle Windows for Particle Adhesion in Cold Spray Using Peridynamic Simulations

Numerical simulations have been extensively used to study particles impacting behavior in cold spraying. However, numerous existing simulation methodologies frequently neglect the consideration of interfacial adhesion, leading to particle decohesion and rebound. Furthermore, the adhesion quality of the deposited coating is significantly affected by spray process parameters, such as particle impact velocity and spray angle. Therefore, we conducted numerical simulations based on the meshless and nonlocal peridynamics (PD) method. A three-dimensional single-particle model was developed to simulate copper particle impacts on a copper substrate, incorporating adhesive forces at particle-substrate interface. Critical velocity, critical spray angle, coating morphology, as well as interface characteristics, were predicted using the proposed model, which was validated by comparing its simulations with literature-based experimental findings. Specifically, within the deposition range investigated, particle adhesion occurred at 500 m/s or higher, indicating a critical velocity of approximately 500 m/s. Furthermore, a critical spray angle of 71° was obtained for a specific powder-substrate combination, below which powder deposition onto the substrate did not occur. These findings contribute to the development of an optimized parameter window for cold spray deposition. The PD simulation approach provides a comprehensive and highly realistic description of the impact and adhesion behaviors during the cold spray coating build-up process.