Deposition characteristic of Al particles on Mg alloy micro-channel substrate by cold spray

Cold spray is a new surface modification method which can be applied to improve Mg alloy anti-corrosion performance. In this study, finite element analysis (FEA) with arbitrary Lagrange Eulerian (ALE) grid method was used to simulate single and multiple Al alloy particles deposition behavior on Mg alloy substrate micro-channel surface. Effects of particle size, velocity, and particle-substrate temperature on the deposition process were studied. Results show that particle-substrate material plastic deformation was distinct when particle impacted at different positions on micro-channel substrate surface. The maximum contact area and energy consumption of the substrate were very distinct. Particle sizes also had important influence on deposition process; it was more conducive to its deformation when particle and Mg alloy micro-channel was of the same size. When multiple particles impacted on micro-channel substrate surface, particle initial velocity and material initial temperature had important influence on coating porosity. Reinforcement of the subsequent particles also played an important role on the formation and quality of cold-sprayed coating.