Cold gas spraying is a relatively new coating process by which coatings can be produced without significant heating of the sprayed powder. In contrast to the well-known thermal spray processes such as flame, arc, and plasma spraying,
in cold spraying there is no melting of particles prior to impact on the substrate. The adhesion of particles in this process is due solely to their kinetic energy upon impact. Experimental investigations show that successful bonding is achieved only above a critical particle velocity, whose value depends on the temperature and the thermomechanical properties of the sprayed material. This paper supplies a hypothesis for the bonding of particles in cold gas spraying, by making use of numerical modelling of the deformation during particle impact. The results of modelling are assessed with respect to the experimentally evaluated critical velocities, impact morphologies and strengths of coatings. The analysis demonstrates that bonding can be attributed to adiabatic shear instabilities which occur at the particle surface at or beyond the critical velocity. On the basis of this criterion, critical velocities can be predicted and used to optimize process parameters for various materials.

Short product description
A ready-to-run Abaqus product that reproduces and validates the key results from the paper “Bonding mechanism in cold gas spraying”: time histories of plastic strain, temperature, and flow stress at critical nodes. Ideal for verification, teaching, or as a baseline for research on cold gas spraying and high-velocity particle impact.

Key benefits

• Saves setup time — run the reference cases and adapt to your materials/velocities.
• Clear instructions for mesh refinement, contact/friction, and thermo-mechanical coupling in Abaqus.