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A contoured nozzle design method for effective cold spray metal coating

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conference contribution
posted on 01.07.2021, 14:42 by Aldo Rona, Florentina-Luiza Zavalan
In cold spraying, a uniform particle distribution of uniform velocity is desirable to achieve a good quality deposition pattern. Whereas many cold spray facilities use conical convergent-divergent nozzles for accelerating the particles, this paper evaluates a contoured axisymmetric nozzle design to enhance the process efficiency. The performance of a conventional conical cold spray nozzle is compared with that of a new axisymmetric nozzle designed with a smooth throat and contoured for a parallel outflow. The new nozzle profile is obtained by the application of two aerospace design codes based on the Method of Characteristics. A two-way coupled Eulerian-Lagrangian Computational Fluid Dynamics formulation is used, where the continuous phase steady motion is predicted by solving the Reynolds-Averaged Navier-Stokes equations with the Shear Stress Transport k-ω model. A Discrete Phase Model computes the motion of the particles carried by the jet. The numerical predictions show that the new nozzle shape delivers a more radially uniform deposition. A higher particle velocity is also obtained at the same operating conditions used by the industry standard nozzle, which is desirable for good particle bonding to the substrate.


Author affiliation

School of Engineering


ICLASS 2021 - 15th Triennial International Conference on Liquid Atomization and Spray Systems


AM (Accepted Manuscript)

Published in

Proceedings of ICLASS 2021

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Spatial coverage

Edinburgh, UK

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