Residual stress characterization from numerical analysis of the multi-particle impact behavior in cold spray

In cold spray, bonding forms between a substrate and the particles and between particles through impact deformation at high strain rates. A prominent feature of the cold spray process is the compressive residual stress that arises during the deposition process. Compressive residual stress on the surface can be beneficial for fatigue resistance. As a post processing technique several applications require surface treatment processes that produce this state of stress on component surfaces such as shot peening, laser shock peening, ultrasonic impact treatment, low plasticity burnishing, etc. In all of these methods, the compressive stress is produced through plastic deformation of the surface region. In a similar manner, the cold spray process induces compressive stress by high speed impact of the sprayed particles on the surface, causing a peening effect. The effects of these variations in the properties of the coatings are rarely reported. Moreover, there are some applications which require minimal residual stresses in the components such as in optics. In this study, we have investigated the residual stress using numerical analysis of the multi-particle impact behavior in cold spray.