Abstract
A contact model that accounts for interfacial cohesion and thermal conduction is developed to investigate the influence of bonding on the final residual stresses build-up in cold spray. The residual stress evolution in the cold sprayed Al-6061 coating on an Al-6061 substrate is investigated via three-dimensional (3D) single-particle and multi-particle impact simulations. It is shown that the interface bonding mainly affects the local residual stress distribution near the interfaces. The residual stresses are largely due to the kinetic peening and bonding effects. The thermal cooling has negligible influence. In general, the peening effect introduces a compressive stress while the bonding effect results in a relaxation to this compressive stress. This work suggests that the interface bonding should be considered as one of the essential factors in numerical modeling of the residual stresses evolution in cold spray.
