ABSTRACT
Kinetic spray or cold spray (CS) is a metal deposition approach of additive manufacturing that is used to repair the damage or corroded components. Cold spray additive manufacturing (CSAM) is a solid-state deposition technique that works under the high-velocity impact of particles using a de Laval nozzle. A convergent section CS nozzle was designed through numerical modeling. The main factors significantly affecting temperature and particle velocity include the length and diameter of the convergent barrel side, accelerating gas and its particle size, pressure, and temperature. In this study, a numerical approach using finite-element methodology (FEM) and Abaqus/Explicit has been integrated with the experimental investigation. Micro-sized metallic particles, especially nickel, have been used as the coating material on the substrate of mild steel at normal temperature. The characterization technique of scanned electron microscopy and transmission electron microscopy has been also used for the validation of this work. FEM with Abaqus/Explicit has been also used to understand the interface bonding between the particle and the substrate.
