Particle-based simulation of cold spray: Influence of oxide layer on impact process

High-speed cold spraying of micro-particles, at temperatures well below their melting point, impinging on desired substrates is a useful emerging additive process. One principal element believed to dramatically influence the bonding strength and final coating quality many metallic cold-spray deposits native oxide layer surface particles substrate. Here, smoothed-particle hydrodynamics (SPH), mesh-free, particle-based method, used simulate cold-spraying, including action layers in deposition processes. The effect increasing particle impact velocity breakup subsequent studied. Particle/substrate quantified via interaction interface found continuously improve with beyond critical velocity. coefficient restitution also calculated for different thicknesses effects diameter oxygen content process are reported compared results from literature. simulation approach reproduce experimentally characterized trends provide insight into mechanisms during bonding.