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<p>High-velocity particle impact is a fundamental process in contact mechanics, underlying techniques such as cold spray and surface peening. This study investigates particle impact on randomly rough surfaces using finite element simulation. Results show that surface roughness intensifies plastic deformation, reduces bonding threshold, and increases substrate residual stress by up to 21%. A crucial mechanistic transition is identified that particle residual stress shifts from hardening-dominated to thermal-softening-dominated regimes as velocity increases, with a critical dimensionless velocity around 0.30. Through dimensional analysis, a theoretical power-law model is developed and validated against simulations, describing the velocity dependence as <InlineEquation ID="IEq1"> <EquationSource Format="TEX">\({\sigma}_{r}\propto {V}_{i}^{1}\)</EquationSource> <EquationSource Format="MATHML"><math> <mrow> <msub> <mi>σ</mi> <mi>r</mi> </msub> <mo>∝</mo> <msubsup> <mi>V</mi> <mrow> <mi>i</mi> </mrow> <mn>1</mn> </msubsup> </mrow> </math></EquationSource> </InlineEquation> below and <InlineEquation ID="IEq2"> <EquationSource Format="TEX">\({\sigma}_{r}\propto {V}_{i}^{-1}\)</EquationSource> <EquationSource Format="MATHML"><math> <mrow> <msub> <mi>σ</mi> <mi>r</mi> </msub> <mo>∝</mo> <msubsup> <mi>V</mi> <mrow> <mi>i</mi> </mrow> <mrow> <mo>-</mo> <mn>1</mn> </mrow> </msubsup> </mrow> </math></EquationSource> </InlineEquation> above the critical velocity. This model provides a practical tool for residual stress control in tribological applications involving high-velocity contact and interfacial adhesion.</p> Graphical abstract <p></p>

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Residual Stress Transition During High-Velocity Particle Impact on Rough Surfaces

  • 期刊论文

  • 发表日期：

    2026年6月22日

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  • Mingjie Liu,
  • He Zhu,
  • Yanwei Liu,
  • Jianqiao Hu

摘要

High-velocity particle impact is a fundamental process in contact mechanics, underlying techniques such as cold spray and surface peening. This study investigates particle impact on randomly rough surfaces using finite element simulation. Results show that surface roughness intensifies plastic deformation, reduces bonding threshold, and increases substrate residual stress by up to 21%. A crucial mechanistic transition is identified that particle residual stress shifts from hardening-dominated to thermal-softening-dominated regimes as velocity increases, with a critical dimensionless velocity around 0.30. Through dimensional analysis, a theoretical power-law model is developed and validated against simulations, describing the velocity dependence as \({\sigma}_{r}\propto {V}_{i}^{1}\) σ r ∝ V i 1 below and \({\sigma}_{r}\propto {V}_{i}^{-1}\) σ r ∝ V i - 1 above the critical velocity. This model provides a practical tool for residual stress control in tribological applications involving high-velocity contact and interfacial adhesion.

Graphical abstract