Investigating the cold spraying process with the material point method

High-velocity impacts of micro copper particles on the copper substrate in the cold spraying process are simulated and investigated with the material point method (MPM). Both the single-particle and the multiple-particle models are built and simulated. The large deformation and fracture phenomena induced by the impact can be well simulated with the MPM owing to its meshfree feature. The final configurations of the sprayed particle and the substrate agree well with the experimental results reported in the literature and the results of other numerical methods. It is observed that the interlocking between the particles and the substrate may be an important contributor to the bonding mechanism. Influences of the impact velocities and impact angles are investigated numerically in detail.