COMPUTATIONAL ANALYSIS OF COLD SPRAY NOZZLE DESIGN’S EFFECT ON PARTICLE ACCELERATION

Oleksandr Shorinov, Nina Savchenko, Oleg Tryfonov, Olga Shypul

Abstract


The subject of this article is the computational analysis of the effect of nozzle geometry on gas dynamics and particle acceleration in cold gas dynamic spraying (CGDS). This study aims to compare the performance of conventional conical nozzles and Method of Characteristics (MOC)-based bell-shaped nozzles in accelerating particles to the critical velocities required for effective coating deposition. The tasks to be solved are as follows: design and model conical and MOC nozzles; conduct CFD simulations of compressible two-phase gas–particle flows in both geometries; analyze velocity, pressure, and temperature distributions along the nozzle and jet regions; and evaluate particle acceleration and velocity distribution for aluminum powder. The following methods were used: numerical modeling of gas–particle flow employing the Navier–Stokes equations with the RNG k–ε turbulence model in ANSYS Fluent 2025 R1, along with Lagrangian particle tracking; computational design of nozzles using MATLAB code based on the Method of Characteristics; and comparison of flow fields and particle dynamics between nozzle configurations. The results show that both nozzles operate under underexpanded jet conditions, but the MOC nozzle accelerates the carrier gas and particles earlier, resulting in more uniform velocity fields and reduced velocity lag between the gas and the dispersed phase. For 25 µm aluminum particles, the MOC nozzle achieves higher particle velocities than the conical nozzle, indicating greater potential for plastic deformation and improved coating adhesion. Additionally, higher exit gas velocities and more stable jet structures were observed in the MOC nozzle, despite the presence of more pronounced boundary-layer vorticity. Conclusions. The scientific novelty of the results lies in establishing the gas-flow acceleration patterns with aluminum powder particles in conical and MOC-based nozzles, optimized for aluminum deposition at 2.5 MPa gas pressure and 650 °C. The MOC-based nozzle enables earlier gas expansion and a more stable free-jet structure, thereby achieving a higher, significantly more uniform powder particle velocity than the conical nozzle under identical spraying conditions.


Keywords


CFD simulation, mathematical modeling, gas flow, supersonic nozzle, ANSYS Fluent, spraying, coating

References


Dykhuizen, R. C. & Smith, M. F. Gas dynamic principles of cold spray. Journal of Thermal Spray Technology, 1998, vol. 7, no. 2, pp. 205–212. DOI: 10.1361/105996398770350945.

Bernard, C. A., Takana, H., Lame, O., Ogawa, K. & Cavaillé, J.-Y. Influence of the nozzle inner geometry on the particle history during cold spray process. Journal of Thermal Spray Technology, 2022, vol.31, no. 7, pp. 1 – 15. DOI: 10.1007/s11666-022-01407-y.

Grujicic, M. J., DeRosset, W. S. & Helfritch, D. Flow analysis and nozzle-shape optimization for the cold-gas dynamic-spray process. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 2003, vol. 217, no. 11, pp. 1603–1613. DOI: 10.1243/095440503771909980.

Shorinov, O., Volkov, A., Dolmatov, A. & Balushok, K. Numerical Simulation of a Modified Nozzle for Cold Spraying. In: Tonkonogyi, V., Ivanov, V., Trojanowska, J., Oborskyi, G. & Pavlenko, I. (eds) Advanced Manufacturing Processes V. InterPartner 2023. Lecture Notes in Mechanical Engineering. Springer, Cham, 2024, pp. 563 - 575. DOI: 10.1007/978-3-031-42778-7_53.

Shorinov, O. V. & Polyviany, S. A. «Simulation of Gas Flow with Nanocomposite Carbon-Containing Powders in Supersonic Nozzle». Metallofizika i Noveishie Tekhnologii, 2022, vol. 44, no. 5, pp. 601–611. DOI: 10.15407/mfint.44.05.0601.

Gabor, T., Akin, S. & Jun, M. B.-G. Numerical studies on cold spray gas dynamics and powder flow in circular and rectangular nozzles. Journal of Manufacturing Processes, 2024, vol. 114, pp. 232–246. DOI: 10.1016/j.jmapro.2024.02.005.

Sakaki, K. The influence of nozzle design in the cold spray process. In: The Cold Spray Materials Deposition Process: Fundamentals and Applications. Woodhead Publishing, 2007, pp. 117–126. DOI: 10.1533/9781845693787.2.117.

Grujicic, M. J., Zhao, C. L., Tong, C., Derosset, W. S. & Helfritch, D. Analysis of the impact velocity of powder particles in the cold-gas dynamic-spray process. Materials Science and Engineering: A, 2004, vol. 368, no. 1–2, pp. 222–230.

Karimi, M., Fartaj, A., Rankin, G., Vanderzwet, D., Birtch, W. & Villafuerte, J. Numerical simulation of the cold gas dynamic spray process. Journal of Thermal Spray Technology, 2006, vol. 15, no. 4, pp. 518–523.

Raoelison, R. N., Koithara, L. L., Costil, S. & Langlade, C. Turbulences of the supersonic gas flow during cold spraying and their negative effects: A DNS CFD analysis coupled with experimental observation and laser impulse high-speed shadowgraphs of the particles in-flight flow. International Journal of Heat and Mass Transfer, 2020, vol. 147, article no. 118894. DOI: 10.1016/j.ijheatmasstransfer.2019.118894.

Krampe, M. & Kuhlenkötter, B. Experimental investigation of the influence of different nozzle exit geometries on the depositing of strands in fused layer modeling. In: Annals of Scientific Society for Assembly, Handling and Industrial Robotics 2023, pp. 13–25. DOI: 10.1007/978-3-031-74010-7_2.

Alonso, L., Garrido-Maneiro, M. A. & Poza, P. A study of the parameters affecting the particle velocity in cold-spray: Theoretical results and comparison with experimental data. Additive Manufacturing, 2023, vol. 67, article no. 103479. DOI: 10.1016/j.addma.2023.103479.

Kun, T., Wenjie, H. & Yurong, W. Optimization of cold spray nozzles based on the response surface methodology. Journal of Engineering Sciences (Ukraine), 2024, vol. 11, no. 1, pp. F1–F11. DOI: 10.21272/jes.2024.11(1).f1.

Gutiérrez de Frutos, J., List, A., Nielsen, S., Gärtner, F. & Klassen, T. Nozzle geometry evaluation for cold spray applications by using 3D-CFD calculations. Journal of Thermal Spray Technology, 2025, vol. 34, no. 3, pp. 570–586. DOI: 10.1007/s11666-025-01945-1.

Sakaki, K., Huruhashi, N., Tamaki, K. & Shimizu, Y. Effect of nozzle geometry on cold spray process. Proceedings of the International Thermal Spray Conference (ITSC 2002), ASM International, March 2002, pp. 385-392. DOI: 10.31399/asm.cp.itsc2002p0385.

Sharma, A. K., Vashishtha, A., Callaghan, D., Bakshi, S. R., Kamaraj, M. & Raghavendra, R. CFD investigation of a co-flow nozzle for cold spray additive manufacturing applications. Journal of Thermal Spray Technology, 2024, vol. 33, no. 7, pp. 1251–1269. DOI: 10.1007/s11666-024-01764-w.

Grass Nunez, J. S., Rojas Perilla, D. A., Barragan De Los Rios, G. A. & Coelho, R. T. Numerical and experimental analysis of gas flow in a coaxial nozzle applied to directed energy deposition (DED). International Journal of Engineering Materials and Manufacture, 2021, vol. 6, no. 3, pp. 102–113. DOI: 10.26776/ijemm.06.03.2021.01.

Hu, W. J. & Shorinov, O. Optimization of technological parameters for cold spraying using the response surface method. Journal of Engineering Sciences (Ukraine), 2024, vol. 11, no. 2, pp. F1–F8. DOI: 10.21272/jes.2024.11(2).f1.

Murphy, J., Schmidt, D., Wang, S. P. & Corradini, M. L. Multi-dimensional modelling of multiphase flow physics: high speed nozzle and jet flows — a case study. Nuclear Engineering and Design, 2001, vol. 204, no. 1–3, pp. 177–190. DOI: 10.1016/S0029-5493(00)00362-9.

Alonso, L., Garrido, M. Á. & Poza, P. An optimisation method for the cold-spray process: On the nozzle geometry. Materials & Design, 2022, vol. 214, article no. 110387. DOI: 10.1016/j.matdes.2022.110387.

Yin, S., Sun, Y., Wang, X., Guo, Z. & Liao, H. Effect of spray angle on temperature distribution within the metallic substrate in cold spraying. Journal of Thermal Spray Technology, 2013, vol. 22, no. 6, pp. 983–991. DOI: 10.1007/s11666-013-9931-x.

Nastic, A., Jodoin, B., Poirier, D. & Legoux, J. G. Particle temperature effect in cold spray: A study of soft particle deposition on hard substrate. Surface and Coatings Technology, 2021, vol. 406, article no. 126735. DOI: 10.1016/j.surfcoat.2020.126735.

Tabbara, H., Gu, S., McCartney, D. G., Price, T. S. & Shipway, P. H. Study on Process Optimization of Cold Gas Spraying. Journal of Thermal Spray Technology, 2010, vol. 20, no. 3, pp. 608–620. DOI: 10.1007/s11666-010-9564-2.

Nastic, A., MacDonald, D. & Jodoin, B. The influence of feedstock powder. In: Materials Forming, Machining and Tribology. Cham: Springer International Publishing, 2020, pp. 33–85. DOI: 10.1007/978-3-030-42756-6_3.

Yin, S., Cavaliere, P., Aldwell, B., Jenkins, R., Liao, H., Li, W. & Lupoi, R. Cold spray additive manufacturing and repair: Fundamentals and applications. Additive Manufacturing, 2018, vol. 21, pp. 628–650. DOI: 10.1016/j.addma.2018.04.017

Nastic, A., & Jodoin, B. Evaluation of heat transfer transport coefficient for cold spray through computational fluid dynamics and particle in-flight temperature measurement using a high-speed IR camera. Journal of Thermal Spray Technology, 2018, vol. 27, no. 8, pp. 1491–1517. DOI: 10.1007/s11666-018-0787-y.




DOI: https://doi.org/10.32620/reks.2026.2.04

Refbacks

  • There are currently no refbacks.