A Physics-Based Computational Model for the Cold Spray Deposition of Composite Coatings

Abstract

Composite coatings with tailored properties can be effectively deposited with the cold spray process via careful control of deposition parameters. To avoid repetitive experiments, numerical models are commonly used to optimize the cold spray deposition process parameters. The present study proposes using a physics-based hybrid computational approach to model the cold spray deposition of Ni-Ti/Al2O3 composite coating used for wear applications. The method involves using point cloud (for the impacting particles) and finite elements (for the deformed splats structures and substrate) to simulate dissimilar particles impact and interactions, plastic deformation, and temperature rise. The approach is computationally efficient and adequately captures the thermo-mechanical deformation resulting from the interactions among dissimilar particles. The simulations are carried out for various combinations of material types, particles sizes and shapes, and impacting velocities. The results from the simulations are analyzed and validated by comparing them with that of previous works. The plastic deformation and temperature rise within the mating bodies increase with increasing particles’ kinetic energies. The Ni-Ti-Al2O3 powder particles lead to higher plastic deformation, temperature rise, and inter-particle bonding due to the presence of the hard Al2O3 particles. The temperature does not rise above melting; however, recrystallization of coating microstructure becomes possible even at a low deposition rate.