Numerical Modeling of Critical Velocity and Deformation Behavior in Cold Spray Using Lagrangian and Arbitrary Lagrangian Technique

The cold spraying process is numerically modeled using Lagrangian and Arbitrary Lagrangian Eulerian (ALE) techniques. The simulations were performed to predict the critical velocity of spherical aluminum particles deposited on the aluminum substrate. ALE technique was found to be more suitable than the Lagrangian technique. Using Lagrangian and ALE techniques, the critical velocity for aluminum was predicted as 605 m/s and 770 m/s. Critical velocity was in between 770-775 m/s, as reported in the literature. The Lagrangian technique's capability is limited in capturing large deformations associated with cold spraying. However, this technique requires less computational ability and is quicker than the ALE technique. The jet formation was prominent in the case of the Lagrangian technique, and hence the difference between the numerically estimated value of critical velocity and experimentally measured velocity is more. The Compression ratio was found to increase with an increase in impingement velocity.