Computational simulation of cold spray coating for optimal injector length

The present study investigates the effect of injector length based on impact velocity, particle temperature, and substrate surface temperature. In this analysis, the substrate material was Steel, and the powder material was Titanium. The geometry used in this analysis was two-dimensional, and the investigation was carried out using an axisymmetric model. The simulation work in this analysis was done using ANSYS software, and the model geometry was attained using SolidWorks. The study reflects the effect of gases on temperature and velocity. Helium is an inert gas; therefore, the velocity of particles was maximum with helium and minimum with pure nitrogen. On the other hand, the temperature of particles and substrate was found to be leading with pure nitrogen under the same operating conditions. Based on the results and observation, the particle injector length of 15 mm was optimal.