Computational simulation on performance enhancement of cold gas dynamic spray processes with electrostatic assist

A real-time computational simulation on the entire cold spray process is carried out by the integrated model of compressible flow field, splat formation model, and coating formation model, in order to provide the fundamental data for the advanced high performance cold gas dynamic spray process with electrostatic acceleration. In this computation, viscous drag force, flow acceleration added mass, gravity, Basset history force, Saffman lift force, Brownian motion, thermophoresis, and electrostatic force are all considered in the particle equation of motion for the more realistic prediction of in-flight nano/microparticle characteristics with electrostatic force and also for the detailed analysis of particle-shock-wave-substrate interaction. Computational results show that electrostatic acceleration can broaden the smallest size of applicable particle diameter for successful adhesion; as a result, wider coating can be realized. The utilization of electrostatic acceleration enhances the performance of cold dynamic spray process even under the presence of unavoidable shock wave.