Effect of non-vertical incidence angles of particles on bonding performance in cold spraying

When high-speed particles are spraying the part with complex bend surface, the majority of particles will intrude and cut off the surface of the part in certain angle, Non-Vertical incidence particles will have an important influence on formation and characteristic of the coating. Based on developed numerical simulation method, the non-vertical impacting behavior of copper particles colliding copper substrate in process of transforming material property was investigated. The join strength, penetration depth and condition of emerging adiabatic shear instability were discussed with single particle of uniform speed and different angles. It is revealed that the deposit effect of cold spray is deteriorating in certain angle collision comparing with the ideal vertical collision; with the increasing incidence angle, the penetration depth of particles is decreased and the join strength is weakened, even can't be embeded into the substrate and leads to the disengagement. Adiabatic shear instability will take place when the normal component of particle velocity excesses critical value.