Abstract
The integrated model of 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 shockwave and particles in 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 diameter for impinging particle velocity exists and the maximum impact velocity of 732 m/s is obtained for the particle diameter of 1.3μm. Particles with the diameter of submicron interacts with shockwave and particles are decelerated prior to the impact. However, the particle can be accelerated considerably by utilizing electrostatic force even in the presence of shockwave. Finally, based on the integrated model, coating thickness in an electrostatic assisted cold spray process is successfully evaluated.
