Comparing Relative Bond Characteristics Between Spherical and Elongated Morphologies for Cold Spray Process Using SPH Simulation

Abstract Under cold spray conditions, the modified Johnson–Cook model was adopted to perform single and multiple particle simulation for spherical and elongated aluminum alloy- Al-6061 feedstock particles. The splat formations were realistically presented; the temperature evolution throughout the deposition process stayed below the melting point of Al-6061, and the feedstock particles exhibited restitution for impact velocities lower than 200 m/s. Feedstock particles with elongated morphology experienced a lower elastic strain energy level than spherical morphology after impact, which implied the relative bond strength was higher for elongated particles than spherical particles. The displacement curves in single particle simulations for both morphologies suggested a spherical particle experienced a greater shock than the elongated particle upon impact. The relative bond strength achieved by multiple particle impact was lower than the single particle impact, even though the displacement curves showed the feedstock particles were individually embedded in the substrate.