Prediction of Critical Velocity during Cold Spraying Based on a Coupled Thermomechanical Eulerian Model

In the present work, a coupled thermomechanical-Eulerian model was developed to calculate particle impact behavior during cold spraying. The model is based on temperature-displacement elements and is capable of nonlinear transient analysis of impact deformation and heat conduction. Simulation results show that heat conduction has a major effect on temperature distribution within the particle, but little influence on particle deformation. The FEA model is also used to calculate critical velocities of commonly sprayed materials and the results are evaluated based on the morphology of deformed particles and plastic strain analysis.