Numerical Analysis of Residual Stress in Cold Sprayed Titanium

Residual stresses, which are crucial to the performance of cold-sprayed deposits, arise from the high-velocity impact of particles that induce compressive stresses through surface peening. Additional factors, such as thermal effects and quenching, further influence the overall stresses nature, e.g., compressive or tensile, as well as their magnitude and distribution. This study uses finite element simulation to explore how cold spray process parameters, including particle velocity, temperature, and substrate conditions, influence the residual stress distribution, magnification, and type in hard/hard cold sprayed material configuration. Specifically, the Johnson-Cook model is used for simulating high strain rate deformation of single splat impact of Titanium splats on a Titanium substrate as a hard/hard material. Our results suggest that temperature and particle impact velocity can effectively change the magnitude and distribution of compressive and tensile residual stresses within the splat, influencing the final residual stresses of the buildup cold sprayed material. These findings are expected to significantly improve the application of titanium cold-sprayed deposition in demanding industrial environments, leading to enhanced adhesion, fatigue resistance, and overall reliability.

Keywords: Cold Spray, Residual Stress, Titanium, Numerical Modelling, Particle Impact