Development of three dimensional multicomponent model for cold spray direct manufacturing process

Cold spray is a rapid deposition process in which particles accelerate to velocities above supersonic speeds (1000-1500m/s) to establish coatings and directly manufacture bulk structures. Earlier, a calibrated k-ε type three dimensional (3D) model revealed the state of cold spray gas conditions (temperature, pressure, velocity). In this study, the aim is to further develop the earlier model. A 3D multicomponent model has been developed for the cold spray that includes Nitrogen (N2) and Helium (He) under supersonic conditions. Multicomponent refers to the coupling of high speed N2/He with surrounding air. The 3D model was validated against three cold spray experiments, namely, substrate temperature measurement, particle image velocimetry (PIV) and particle location measurements. The outcomes of 3D model were within 10-15% accuracy when compared against experimental results. It is believed that the model outcomes would be useful to optimize system design, deposition process, and mechanical properties of the additively manufactured cold spray structures.