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Cold spray is a material deposition process used   to deposit metallic features for use in applications such   as corrosion prevention, dimensional correction and repair,   and wear resistant coatings. Micro Cold Spray Direct   Write (MCS-DW) is a variant of the cold spray process in   which metal particles are accelerated and focused to print   fine features on flexible and rigid substrates with no postprocessing   required. This paper presents results of numerical   studies on the flow of 2 µm and 6 µm diameter silver   particles through a converging-diverging micro nozzle with   helium gas. The flow of helium was simulated by solving   Navier Stokes equation using commercial software. The   trajectory and velocity of the aerosol particles were determined   using a Lagrangian particle tracking algorithm with   a combination of Stokes drag force and Saffman lift force   acting on the particles. A comparison of the effect of different   corrections applied to Stokes and Saffman forces as   well as the effect of Magnus force on the trajectory and velocity   of aerosol particles is studied. The effect of particle   rotation creating Magnus force is found negligibly small   compared to Saffman force for particles of 2 µm diameter,   however, the effect is found to be significant for particles of   6 µm diameter. A proposed converging-diverging nozzle is   shown capable of accelerating silver particles to velocities   as high as 600 m/s and enables aerosol beam widths as thin   as 50 µm.

Aerosol Flow Through a Converging-Diverging Micro-Nozzle