Abstract
In this study, finite element analysis and experimental observation are used to evaluate the effect of substrate hardness and spray angle on the deposition of cold-sprayed Ti particles. It is found, in the case of Cu substrates, that both the particle and substrate deform during impact, resulting in a large contact area. Metallurgical bonding is highly likely under such conditions, facilitating formation of thick coatings. In the case of Al substrates, although the contact area is smaller, Ti particles are trapped by the softer substrate material, resulting in mechanical interlocking and a relatively thick coating. In the case of stainless steel substrates, mechanical interlocking does not occur due to the relative hardness of the material, which limits coating thickness. The results of the study also show that decreasing the spray angle reduces interfacial contact area and coating thickness, while increasing porosity.
