Simulation of the Cold Spray Deposition Process for Aluminum and Copper using Lagrangian, ALE and CEL Methods

The numerical methods play an important role in researching the cold spray deposition process. Quite a number of studies have focused on the impact and deformation behaviors of particle and substrate by numerical simulation. The particle velocity will determine the amount of kinetic energy available for plastic deformation. Owing to the feasibility of coating formation by cold spray and the availability of relevant material data in the literature, copper (Cu) and aluminum (Al) were chosen as reference materials for the modeling of particle impact on substrates. This chapter investigates particle deformation using Lagrangian, arbitrary Lagrangian-Eulerian (ALE) and coupled Eulerian-Lagrangian (CEL) reference frames. The reliability of these three different modeling approaches on a single-particle impact are studied and compared. The effects of impact velocity, temperature of the particle and contact angle are then discussed. Finally, the first numerical results of multiple impacts are presented.