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<p>The velocity at which particles impact the substrate during cold spray processes is a critical factor influencing both the quality of the deposition and the efficiency of metallic particle adherence. The nozzle serves as the primary source of aerodynamic force in the cold spray system and significantly influences the impact velocity of particles. This study proposes an optimized design method for cold spray nozzles based on nozzle-flow dynamics, aiming to enhance aerodynamic acceleration and thereby improving the deposition efficiency. Initially, a nozzle-flow model is developed based on the nozzle’s geometric configuration and subsequently modified to incorporate the specific characteristics of cold spray processes. Following this, an optimized nozzle design model is established to identify the maximum outlet flow velocity under conditions of zero outlet pressure difference, integrating considerations of practical manufacturing constraints and aerodynamic performance criteria. Ultimately, an optimized solution is obtained. The results indicate that the theoretical maximum outlet flow velocity can reach 944.6&#xa0;m/s, while simultaneously enhancing aerodynamic acceleration effects and maintaining an optimal outlet flow pattern. Furthermore, simulation analyses and particle acceleration experiments are performed on the optimized nozzle. The simulation results demonstrate that the optimized nozzle exhibits superior acceleration performance across various process conditions. Experimental findings further reveal that the average particle velocity at the nozzle outlet is 531&#xa0;m/s, confirming that particles undergo significant entrainment acceleration within the nozzle-flow.</p>

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Optimized Design for Improved Aerodynamic Performance of Cold Spray Nozzles

  • 期刊论文

  • 发表日期：

    2026年1月8日

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  • Yingdong Wu,
  • Hui Xie,
  • Chengchuan Sun,
  • Jing Lu

摘要

The velocity at which particles impact the substrate during cold spray processes is a critical factor influencing both the quality of the deposition and the efficiency of metallic particle adherence. The nozzle serves as the primary source of aerodynamic force in the cold spray system and significantly influences the impact velocity of particles. This study proposes an optimized design method for cold spray nozzles based on nozzle-flow dynamics, aiming to enhance aerodynamic acceleration and thereby improving the deposition efficiency. Initially, a nozzle-flow model is developed based on the nozzle’s geometric configuration and subsequently modified to incorporate the specific characteristics of cold spray processes. Following this, an optimized nozzle design model is established to identify the maximum outlet flow velocity under conditions of zero outlet pressure difference, integrating considerations of practical manufacturing constraints and aerodynamic performance criteria. Ultimately, an optimized solution is obtained. The results indicate that the theoretical maximum outlet flow velocity can reach 944.6 m/s, while simultaneously enhancing aerodynamic acceleration effects and maintaining an optimal outlet flow pattern. Furthermore, simulation analyses and particle acceleration experiments are performed on the optimized nozzle. The simulation results demonstrate that the optimized nozzle exhibits superior acceleration performance across various process conditions. Experimental findings further reveal that the average particle velocity at the nozzle outlet is 531 m/s, confirming that particles undergo significant entrainment acceleration within the nozzle-flow.