Abstract
Computational Fluid Dynamics (CFD) simulation is an effective method to optimize cold spray process parameters and coating quality. The objective of this work is to construct a CFD model to directly investigate influence of the process parameters such as pressure and carrier gas composition on the particles. This work describes a detailed study of the CFD approach and carrier gas composition, and how it affects the average particle velocity. A model of 3-dimensional nozzle with chamber and particle injector was used to generate the flow field of Ti6Al4V particles with help of compressed carrier gas such as nitrogen, helium at supersonic speeds. Particles are accelerated by the carrier gas to a very high velocity, resulting in plastic deformation upon impact with a solid substrate positioned at specific standoff distance. An optimum average particle velocity is found using CFD simulation for various compositions of carrier gas for a given particle size distribution.
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