Influence of Nozzle Expansion Ratio of Circular and Rectangular Cross-Section Nozzle on Velocity and Temperature of Copper Particle with HP Cold Spraying by Computational Fluid Dynamics and Experimental Analysis

This study compares the performance of circular and rectangular cold spray nozzles based on numerical simulations and experimental results. It shows how nozzle geometry and gas pressure affect the velocity and temperature of copper particles at various points in their travel. The goal of the investigation is to establish a nozzle design that achieves a uniform spray pattern with suitable particle impact velocity for the materials and temperatures involved. It was found that a rectangular nozzle with an expansion ratio in the range of 11-12 can provide a more uniform particle velocity with high deposition efficiency at a reasonable gas pressure.