Cold spray deposition is a process in which bonding between solid microscale particles and a substrate occurs due to high energy impact. In this process, adhesion forms between the impacted particle and the substrate within a certain multi-parameter (material, temperature, particle size, etc.)-dependent impact velocity range. The present work analyzes the effects of particle diameter (for a range of 10-60 µm) on the adhesion of thermoplastic PEEK particles on PEEK substrates using a combined numerical-analytical approach. Our findings indicate that a maximum critical velocity (i.e., impact velocity required for a successful bond formation) of ~360 m/s is required for cold spraying of 10 µm PEEK particles at room temperature. The critical velocity decreases at higher temperatures and for particle diameters in the range of 10 to 40 µm. The predicted critical velocity is shown to increase again for particles with 60 µm diameter. For PEEK particles with diameters from 10 to 60 µm, the critical velocity window is determined to be in the range of 277-360 m/s. The velocity window decreases to 208-270 m/s if the spray temperature is increased to 150°C, i.e., slightly above the nominal glass transition temperature of PEEK.

冷喷涂沉积是一种由于高能量冲击而在固体微米级颗粒和基材之间发生结合的过程。在这个过程中，在特定的多参数（材料、温度、颗粒尺寸等）相关的冲击速度范围内，在受冲击的颗粒和基材之间形成粘附。目前的工作使用组合数值分析方法分析了粒径（范围为 10-60 µm）对热塑性 PEEK 颗粒在 PEEK 基材上的附着力的影响。我们的研究结果表明，最大临界速度（即，在室温下冷喷涂 10 µm PEEK 颗粒需要~360 m/s 的成功粘合形成所需的冲击速度。临界速度在较高温度下和粒径在 10 至 40 µm 范围内时会降低。对于直径为 60 µm 的颗粒，预测的临界速度显示再次增加。对于直径为 10 到 60 µm 的 PEEK 颗粒，临界速度窗口确定在 277-360 m/s 的范围内。如果喷涂温度增加到 150°C，即略高于 PEEK 的标称玻璃化转变温度，则速度窗口会降低到 208-270 m/s 。