Particle deformation and coating deposition behavior in cold spray additive manufactured aluminum deposit on copper substrate by simulation and experiment

In this study, the particle deformation and coating deposition behavior in cold spray additive manufactured (CSAM) aluminum deposit on copper substrate were studied by simulation and experiment. The mechanisms of single particle impact deposition during CSAM were investigated using simulation modeling and the numerical simulation results were validated. The effect of particle collision velocity, preheating temperature and size of particle on CSAM process were studied. The porosity of the coating sprayed by powder particle with large size is smaller than that of the coating with small size, and the quality of bonding surface between coating and substrate obtained by large particle is significantly better than that of the small particle. The microstructure of the substrate after CSAM process with small particle size powder at the gas pressure 2.2 MPa was analyzed. The bonding strength of coating with large particle size powder is greater than that of small particle size powder under the same gas pressure. The particle deformation of the coating side deposited by small particle powder after tensile fracture is significantly lower than that of the coating prepared by the large particle powder.