Abstract The cold spray (CS) process is unique due to its high strain rate deformation and particle deposition in solid state. In situ investigation of this process is challenging. Therefore, numerical methods have been used to simulate this process and provide a better ground for furthering the understanding of the process physics. Metallurgical bonding occurs during the deformation process at the particle/substrate interface during coating build-up. Up to now, several studies have been performed to predict the material behavior during this process. Although several studies have been done to predict the bonding in CS, none of them was able to show the occurrence of localized metallurgical bonding. In this study, a novel modeling method is proposed to predict the occurrence and strength of localized metallurgical bonds in the CS process through finite element method. The process physics and implementation method are explained in details. Critical velocities of aluminum, copper, and nickel were predicted and compared with experimental data to validate the method. In addition, the proposed method is able to show the localized metallurgical bonding at the interface between particle and substrate. Comparison between the predicted bonding area with the proposed method and experimental data from the literature showed good agreement. Graphic Abstract

中文翻译：

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基于物理的有限元建模方法预测冷喷涂中的金属结合

摘要 冷喷涂 (CS) 工艺因其高应变率变形和固态颗粒沉积而具有独特性。这一过程的原位调查具有挑战性。因此，数值方法已被用于模拟该过程，并为进一步了解过程物理提供更好的基础。冶金结合发生在涂层堆积过程中颗粒/基材界面的变形过程中。到目前为止，已经进行了多项研究来预测该过程中的材料行为。尽管已经进行了几项研究来预测 CS 中的结合，但没有一项研究能够显示局部冶金结合的发生。在这项研究中，提出了一种新的建模方法，通过有限元方法预测 CS 过程中局部冶金键的出现和强度。详细解释了过程物理和实现方法。预测铝、铜和镍的临界速度并与实验数据进行比较以验证该方法。此外，所提出的方法能够显示颗粒和基材之间界面处的局部冶金结合。用所提出的方法预测的粘合面积与文献中的实验数据之间的比较显示出良好的一致性。图形摘要 和镍被预测并与实验数据进行比较以验证该方法。此外，所提出的方法能够显示颗粒和基材之间界面处的局部冶金结合。用所提出的方法预测的粘合面积与文献中的实验数据之间的比较显示出良好的一致性。图形摘要 和镍被预测并与实验数据进行比较以验证该方法。此外，所提出的方法能够显示颗粒和基材之间界面处的局部冶金结合。用所提出的方法预测的粘合面积与文献中的实验数据之间的比较显示出良好的一致性。图形摘要