Effect of parameters of cold sprayed Cu particles on its impacting behavior

The impacting behavior of Cu particle upon Cu substrate in cold spraying was studied using the finite element analysis, involving the effects of particle velocity and temperature prior to impact on the deformation behavior, temperature increment and contact area at the particle-substrate interface. It was found that with increasing the particle impact velocity the flattening ratio, temperature increment and contact area at the interface increase. It was confirmed that the critical velocity for the onset of shear instability of particle was consistent with that for particle deposition. As the particle velocity is higher than the critical one, the flattening ratio, temperature increment and contact area at the interface increase more significantly, which will benefit the formation of the bond between particle and substrate. With the increase of particle temperature the temperature at the interface increases significantly. The relatively high temperature achieved the melting point of particle material at the localized contact zone may promote the formation of the metallurgical bonding in the coating.