Effect of powder mixture composition on the deposition efficiency in cold spay: Modelling and experimental validation

Abstract

In this paper, a new semiempirical probability model, allowing for prediction of the composition of multimaterial cold spray coating in dependence on the initial percentage of blend components, is developed and applied. The proposed modeling approach takes into account the deposition efficiencies and the particle sizes of each component of the spraying powder blend. The experimental validation using several Cu/Cr2C3NiCr mixtures with different percentages of copper and cermet powders showed that the simulation results were in a good agreement with the experimental data. It was demonstrated that the deposition efficiency of the Cr2C3NiCr cermet powder strongly decreased when its mass percentage in the Cu/Cr2C3NiCr mixture increased from 5% to 75%. It was also shown that the dependence of the Cr2C3NiCr content in the coating on the initial percentage in the blend was nonlinear and the standard rule of mixtures was not applicable for prediction of copper-cermet coating composition.