Numerical modelling of particle impact and residual stresses in cold sprayed coatings: A review

Abstract Cold spray technology provides protective coatings, additive manufacturing and repair to a wide array of industrial sectors. Alternative tags for cold include, kinetic metallisation, fusion, hypersonic spray, gas dynamic printing, manufacturing. These processes employ the same physics principles accelerating micrometre-sized particles supersonic velocities that impact adhere onto suitably prepared substrate. Numerical modelling has been used extensively study particle modelling. The prediction critical velocity, deformation mechanism and, more recently, residual stresses have areas interest evaluated by numerical methods such as Lagrangian, Eulerian, Smoothed Particle Hydrodynamics, Coupled Eulerian-Lagrangian, Molecular Dynamics. crucial findings these models are summarised, their comparative outcomes assessed with analysis merits weaknesses. process parameters applied in simulations diameter, pre-heat temperature material chemistry is compiled. experimental techniques stress measurements; X-ray diffraction, neutron removal, curvature measurement techniques, concisely reviewed from context being deposits.