Modeling of Particle Consolidation by Cold Spray

To fully understand particle interactions with both substrate and neighboring particles, Finite Element Analysis (FEM) of particle agglomeration impact onto substrate was developed. To investigate particle/particle bonding mechanism, two dimensional models for various initial densities of deposited stainless steel particles has been built. In the model the stainless steel powder was deposited onto copper substrate. The results obtained from simulations show the influence of particle agglomeration density on stress and strain state. Both plastic strains, stresses and dynamics of the process has been investigated. The model was verified and compared with metallographic structures of real coatings.