Abstract
The cold spraying process is analyzed by numerical modeling of the impact between a single spherical particle and a substrate; the effects of impact velocity and spray angle of a particle on the particle and substrate deformation behavior were investigated. It was found that much localized stress, localized strain, and localized heating are present near the particle/substrate interface. When impact velocity exceeds a critical velocity, a jet-type flow of material at the interface was formed. High particle/substrate contact pressures and better developed interfacial jets appear to be the major factors controlling the strength of interfacial bonding. As the particle impact velocity or spray angle increases, the length of interfacial jets increases and it may strengthen the bonding of the particle and the substrate.
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