Thermal effect of high-velocity particle impingements on coating quality in cold gas dynamic spray operations

This investigation is aimed to evaluate thermal effects of the high-velocity particle impingement on the coating quality in CGDS (cold gas dynamic spray). To achieve this, the authors used an explicit time integration approach to predict interface temperatures and deformation profiles of the substrate, as well as, their relationship in commercial solver ABAQUS 6.13. Copper (Cu) and aluminum (Al) materials were specified to particle and substrate, respectively. Two essential process parameters, including six different impact velocities (300, 400, 500, 600, 700, 800 m/s) and three different particle sizes (1, 5, 15 µm), were involved in all simulations. There are very good agreements between the simulated and the published that the non-uniform interface temperature and the poor/failure particle deposition have the direct relationship with either impact velocity or particle size. Once again this study strongly demonstrates the thermal effect of the high-velocity particle impingement on coating quality in CGDS, in turn providing insights into process parameter selection.