Monte Carlo Simulation of the Cold Spray Process of Mixtures of Metal and Ceramic Powders

During cold spraying of ceramic and metal mixtures, there is an interaction between the ceramic and metal particles during the spray process; as a result, under certain conditions, a non-monotonic dependence of deposition efficiency on the content of ceramic particles in the initial powder mixture is observed. In the present work, a numerical Monte Carlo model is put forward for the first time to simulate such behavior of deposition efficiency. The calculation results were compared with the available experimental data. It is shown that, with a proper choice of the values of involved model parameters, one can invent an adequate quantitative description of both the behavior of the deposition efficiency of the mixture and the behavior of the ceramic content of the coating. Additionally, the effects of particle size, particle size distribution, and deposition efficiency of pure metal powder are discussed.