Modeling the effect of impact angle on deposit growth in cold spray processes

We develop a continuum-based physical and mathematical model to investigate coating growth in the cold gas dynamic spray (cold spray) process. The model accounts for collisions between feedstock powder particles and the substrate (or deposited coating) surface across a range of impact angles. Simulations of coating deposition onto a substrate with a wavy surface topography, using a nozzle translating at a constant velocity, reveal distinct deposition conditions on the descending and ascending slopes of the substrate. Further simulations incorporating forward and backward nozzle tilt angles relative to the translation direction identify an optimal impact angle that maximizes the resulting coating thickness, corresponding to peak deposition efficiency.