3. Modeling Cold Spray

Particle/substrate interaction during cold spray (CS) deposition and the resultant bonding are of great importance because they affect coating characteristics. Experimental studies and computational modeling have been performed to get a better understanding of the bonding mechanism during CS as well as its mechanical behavior under different loading conditions. This chapter focuses on modeling approaches and is composed of four sections. In the first three sections, different approaches to model the impact of a single particle and the criteria to relate it to the bonding in CS are discussed. Section 3.1 discusses adiabatic shear instability and the Lagrangian approach to study impact phenomena. Section 3.2 is about the hybrid Lagrangian-analytical approach and uses energy criteria to assess bonding in CS. Section 3.3 uses the Eulerian framework to study material jet formation to analyze bonding in CS. These approaches are devoted to the impact phenomenon of particles to the substrate. In Sect. 3.4, the first attempt to model a consolidated coating is proposed. The model is used to understand the effect of defects such as interparticle boundaries and subsequent splat boundary cracking on the mechanical behavior of CS coatings.