A numerical study of Thermal spraying process is required for optimizing performance and
gun design for spraying various materials. Cold spray process is a new technique of thermal
spray process which is used in industries and very limited data is available. This thesis presents
an investigation on the powder stream characteristics in cold spray supersonic nozzles. This
work describes a detailed study of the various parameters, namely applied gas pressure, gas
temperature, size of particles, outlet gas velocity, dimensions of the nozzle on the outlet
velocity of the particles. A model of a two-dimensional axisymmetric nozzle was used to
generate the flow field of particles (copper or tin) with the help of a carrier gas (compressed)
stream like nitrogen or helium flowing at supersonic speed. Particles are dragged by the carrier
gas up to high velocity magnitudes, resulting in severe plastic deformation processes upon
impact with a solid substrate positioned at the distance SoD (Standoff Distance).
ANSY
