ABSTRACT Copper-Zinc and its alloys are extensively used for the corrosion protection of the metal substrate surfaces like steel. Cold gas dynamic spraying (CGDS) is a material coating technique in which metal particles directly adhere to the substrate surface at a relatively low temperature. Numerical simulation (CFD) is a better alternative to understanding CGDS as compared to experimental data due to less expenditure and less energy consumption in CFD. Optimisation of CGDS can be done either by varying the process parameters or by improving the design of the de-Laval nozzle. In this study, the Response Surface Methodology (Central Composite Design) was used to optimise cold spray deposition efficiency by using a 2-D axisymmetric model by varying the process parameters such as carrier gas temperature, stand-off distance, and particle size. Various models were used to predict the critical velocity and erosion velocity. All the process parameters under consideration were found significant in analysing the model by ANOVA. Copper-Zinc Alloy (C93200) particle size is varied from 2.96 µm to 87.04 µm and carrier gas temperature is varied from 287.78K to 708.22K. With the increase in carrier gas temperature and particle size diameter, critical velocity decreases resulting in improved deposition efficiency.
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