Three-Dimensional Modeling of Cold Spray for Additive Manufacturing

The cold spray process can be used to form three-dimensional objects following the layer-by-layer approach which is called cold gas dynamic manufacturing or cold spray additive manufacturing (CSAM). In this study, a three-dimensional simulation of CSAM for a high-pressure nozzle with axial powder injection is investigated. During the manufacturing of a desirable object by CSAM, formation of the sharp edges, inclined surfaces, stagnation points, and corners will inevitably influence the trajectories of the particles. This leads to dispersion and lack of particle deposition in these areas which can eventually reduce the precision and efficiency of the deposition process. Three different objects of a cylinder and two frustums with different angles have been numerically simulated on a substrate to represent typical additively manufactured parts. Particle trajectories and impact conditions, i.e., size and velocity distributions, with and without these objects, have been compared. The results of numerical modeling provided useful information for understanding the limitations and challenges associated with CSAM, which can help us to improve the quality and precision of particle deposition.