Numerical and experimental analysis of copper particles velocity in low-pressure cold spraying process

Thermodynamic aspects of low-pressure cold spraying process with air as a working gas were simulated using 1-D isentropic approximation and ANSYS Fluent CFD ver. 14.5 software. The simulation was completed with the help of Abaqus CAE software, which was used to find out the parameters causing adiabatic shear instability. The critical velocity of spherical and dendritic copper particles was specified. The experimental verification of the simulation was realized using a self-built CCD camera-based diagnostic system with laser light illumination. Moreover, the experimental investigation of copper particles after impact onto substrate was realized with the use of scanning electron microscope (SEM). The carried investigation proofed the important difference in impact behaviour between dendritic and spherical powders.