Numerical Simulation and Experimental Study of Deposition Behavior for Cold-Sprayed Nano-Structured HA/70wt.%Ti Composite Coating

This study employs numerical simulations and experiments to examine the cold spray deposition of nanostructured hydroxyapatite (Ca₁₀(PO4)₆(OH)₂, HA)/70wt.%Ti composite particles under different processing conditions, based on the features of nanocomposites that strengthen interfacial adhesion and improve coating interfacial strength. Using ABAQUS/CAE combined with LS-PrePost 4.9-x64 software, the deposition behavior of the composite particles during deposition under various impact velocities was analyzed, along with the stress of the HA and Ti particles within the composite particle. The deposition behavior of both single and multiple composite particles under different gas temperatures was studied through cold spray experiments, and composite coatings were fabricated. The microstructure and phase composition were analyzed using scanning electron microscopy (SEM) and X-ray diffraction (XRD). The results showed that the numerical simulations were consistent with the experimental analyses. As the particle velocity or gas temperature increased, the degree of particle deformation upon deposition became more pronounced, accompanied by phenomena such as cracking or fragmentation and splashing rebound. At a gas temperature of 700 °C, both the bonding density of individual particles and the bonding effectiveness of multi-particle deposits were lower than those achieved at 500 °C. The coating prepared at a gas temperature of 500 °C exhibited a flatter surface, better overall bonding with the Ti interlayer, and higher internal density.