In cold spray, high gas temperatures and high velocity impact of particles introduce complex thermal and stress histories in the coating layers and the substrate. It is crucial to understand the interplay between temperature evolution and residual stress development as the residual stresses could potentially cause distortion and/or delamination. In this study, a system-level cold-spray deposition model is developed. The model includes a moving heat source, material addition and thermo-mechanical stress analyses. The heat source model is first validated by qualitatively comparing the thermal history with experimental measurements from literature. The system-level model is then used to calculate the residual stresses and distortion in the cold-sprayed Cu/steel system. The influence of the spray path on the residual stress development is systematically analyzed. The corresponding interface residual stress states are also examined for the different spray paths. Simulation results indicate that the thermo-mechanical analysis using the developed system-level model can provide an effective way to assist in optimizing the cold-spray coating deposition strategy and improve the coating performance.

中文翻译：

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冷喷涂中的热机械变形历程和残余应力分布

在冷喷涂中，高气体温度和粒子的高速冲击会在涂层和基材中引入复杂的热和应力历史。了解温度演变和残余应力发展之间的相互作用至关重要，因为残余应力可能会导致变形和/或分层。在这项研究中，开发了系统级冷喷涂沉积模型。该模型包括移动热源、材料添加和热机械应力分析。首先通过将热历史与文献中的实验测量值进行定性比较来验证热源模型。然后使用系统级模型计算冷喷涂铜/钢系统中的残余应力和变形。系统分析了喷射路径对残余应力发展的影响。还针对不同的喷射路径检查了相应的界面残余应力状态。仿真结果表明，使用开发的系统级模型进行热机械分析可以提供一种有效的方法来辅助优化冷喷涂涂层沉积策略并提高涂层性能。