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Study on Process Optimization of Cold Gas Spraying

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Abstract

Cold gas dynamic spraying is a relatively new spray coating technique capable of depositing a variety of materials without extensive heating. As a result the inherent degradation of the powder particles found during traditional thermal spraying can be avoided. The simplicity of this technique is its most salient feature. High pressure gas is accelerated through a convergent-divergent nozzle up to supersonic velocity. The powder particles are carried to the substrate by the gas and on impact the particles deform at temperatures below their melting point. Computational modeling of thermal spray systems can provide thorough descriptions of the complex, compressible, particle-laden flow, and therefore can be utilized to strengthen understanding and allow technological progress to be made in a more systematic fashion. The computational fluid dynamic approach is adopted in this study to examine the effects of changing the nozzle cross-section shape, particle size and process gas type on the gas flow characteristics through a cold spray nozzle, as well as the spray distribution and particle velocity variation at the exit.

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Acknowledgments

The authors would like to thank Dr Zhiwei Hu (Reginald Platt Lecturer in Civil Aviation, University of Southampton) for providing a program for computing the method of characteristics. The authors gratefully acknowledge the financial support from the EC FP7 Simuspray project (Grant No. 230715).

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Authors and Affiliations

  1. Energy Technology Research Group, School of Engineering Sciences, University of Southampton, Highfield, Southampton, SO17 1BJ, UK

    H. Tabbara & S. Gu

  2. Department of Mechanical, Materials and Manufacturing Engineering, University of Nottingham, University Park, Nottingham, NG7 2RD, UK

    D. G. McCartney, T. S. Price & P. H. Shipway

Authors
  1. H. Tabbara
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  2. S. Gu
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  3. D. G. McCartney
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  4. T. S. Price
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  5. P. H. Shipway
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Correspondence to S. Gu.

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Tabbara, H., Gu, S., McCartney, D.G. et al. Study on Process Optimization of Cold Gas Spraying. J Therm Spray Tech 20, 608–620 (2011). https://doi.org/10.1007/s11666-010-9564-2

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  • DOI: https://doi.org/10.1007/s11666-010-9564-2

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