We are pleased to share our paper titled “Large-scale multi-particle cold spray simulation framework for deposit morphology and deformation analysis” that was recently published in Additive Manufacturing.
In this study, a high-fidelity open-source multi-particle impact framework (Free2Spray) is developed to simulate large-scale (>10,000 particles) CS deposition at a considerably convenient computational cost. The model can accurately track material changes during deposition by splitting the process into sections, each with randomly placed particles. The developed framework is proven to accurately predict the shape profiles and surface roughness of experimental single-layer single-track deposits under various nozzle scanning speeds and reproduces the experimental cross-sectional particle deformation and flattening ratios. Compared with the standard Eulerian schemes, the proposed framework reduces the computational time and memory usage by 34% and 35%, respectively.
