Computational simulation of cold spray process assisted by electrostatic force

The integrated model of compressible thermofluid, splat formation and coating formation for the cold spray process has been established. In-flight behavior of nano-micro particles and the interaction between the shock wave and the particles in a supersonic jet flow impinging onto the substrate and further effect of electrostatic force on the particle acceleration are clarified in detail by carrying out a real-time computational simulation. The optimal particle diameters for an impinging particle velocity exceeding critical velocity exist. Particles with the diameter of submicron interact with shock wave and particles are decelerated prior to the impact. However, the particles can be accelerated considerably by utilizing electrostatic forces even in the presence of unavoidable shock waves. Finally, based on the integrated model, the coating thickness in an electrostatic assisted cold spray process is evaluated.

Graphical AbstractA real-time computational simulation on the entire cold spray process has been carried out by establishing the integrated model of compressible thermofluid field, splat formation and coating information. The interaction between the nano/micro particles and shockwave, substrate is discussed in detail. Furthermore the effect of electrostatic acceleration on the coating formation is clarified. The results show that electrostatic force effectively accelerates especially submicron particles and consequently the coating region can be broadened widely.Figure optionsDownload as PowerPoint slide