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In this study, surface modification and deformation behaviour of different engineering materials were microscopically examined by an approach called cold spray additive manufacturing (CSAM). The CSAM is a layer-by-layer deposition technique for repairing and coating the deteriorated or dimensionally unstable surface. Furthermore, in this study, both the experimental and numerical investigation have been carried to understand the surface modification approach. In the experimental procedure, the de Laval nozzle accelerates the microsize particle at a high velocity on the substrate to obtain the uniform surface coating. Engineering materials like copper, aluminium, titanium and mild steel were probed with different ranges of velocities. Additionally, an explicit/Abaqus finite element approach was used to investigate the bonding between particle and substrate by using the high velocity of particles. At the interface, refining meshing size reduces the beginning velocity for adiabatic shear instability (ASI). For the different combinations of particles and substrates like copper/copper, aluminium/aluminium, titanium/aluminium, aluminium/ titanium, and copper/mild steel at perpendicular impact, the adiabatic shear instability was numerically estimated. Deformation behaviour for multi-impact has also been seen with different particle diameter sizes to determine coating phenomenon. Furthermore, the characterisation technique called scanning electron microscopy (SEM) also showed the uniform coating on the substrate.

A sustainable ecofriendly additive manufacturing approach of repairing and coating on the substrate: cold spray