Film Surface Characterization in Cold Spray Using Advanced Numerical Modeling and Simulation Techniques

Abstract

In cold spray, even when the initial properties are within the critical values for deposition, the multi-impact process is much more complex to ensure a 100% deposition. In inelastic impact, part of the initial kinetic energy of the particles at impact is lost through plastic deformation. After impact and subsequent restitution, unbounded particles will be ejected through rebound forces or material jetting at erosion. Observation of the final kinetic energies achieved in the particles after impact was used as criteria for a rough estimate of the coating process. The surface roughness increased with reduced deposition efficiency. The interface roughness was less affected by this process. Qualitative comparison to experimental results shows some closer correlations with some of the surfaces of experimentally obtained surfaces in cold spray. This could provide some of the answers to the underlying mechanisms in which the cold spray surfaces are generated. 