MODELING COLD SPRAY DEPOSITION OF THERMOPLASTIC POLYMERS: EFFECTS OF IMPACT ANGLE AND TEMPERATURE

Cold spray additive manufacturing is gaining popularity for polymers due to its low operating temperature and reduced manufacturing time. In the present study, the likeon- like impact of single thermoplastic polymer (polyether ether ketone, PEEK) particles on PEEK substrates is modeled to explore the effects of impact angle, initial particle temperature, and impact velocity on cohesion. The particle impact angle varies from 30o to 90o with 15o intervals for impact velocities ranging from 200 to 1000 m/s. Particle temperature in each case is varied from room temperature to the glass transition temperature of PEEK. Results obtained herein provide an insight into the energy balance and the temperature-velocity conditions likely to lead to bond formation. Modeling results demonstrate that the likelihood of bond formation increases with an increase in impact angle, particle temperature, and velocity, at the cost of bond strength.