Atomic simulation of crystal orientation effect on coating surface generation mechanisms in cold spray

Cold spray (CS) as a new surface modification method is widely applied in improving surface quality. The effect of crystal orientation of powder particles on coating surface generation mechanisms in cold spray is systematically investigated by molecular dynamics (MD) simulations in this work. The amorphization tendency and temperature distribution in the jetting region in our simulation are consistent with previous experimental results. In particular, our results show that crystal orientation affects the interactions between the powder particles and the surface of the substrate dramatically, leading to different atomic stress distribution, dislocation density evolution and microstructure evolution processes in the particle/substrate interface region for powder particles with different crystal orientations. The coating surface generation mechanism related to the slip plane system will be discussed.