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Access Type

Open Access Thesis

Document Type


Degree Program

Mechanical Engineering

Degree Type

Master of Science in Mechanical Engineering (M.S.M.E.)

Year Degree Awarded


Month Degree Awarded



Compared to traditional thermal spray, cold spray as a new emerging surface treatment eliminates or substantially reduces phase transformation of deposited material and reduces coating porosity. Therefore, the appearance of this new type of surface treatment and additive manufacturing process has attracted considerable attention from researchers. In this research, three-dimensional modeling of Al6061-T6 particle impact and cohesion process was simulated by utilizing commercial finite element analysis (FEA) software ABAQUS/Explicit. To guarantee that a stable bonding phenomenon can be realized in the scope of physical validity, a built-in cohesive contact behavior model was implemented in the simulation to understand the bonding phenomenon. A non-planar surface was introduced to replace the usual planar impacted surface to mimic micron-scale curvature of the sprayed target in the real condition. Simulation models of spraying particles impact on positions with spray angle corresponding to 90°, 80°, 70° were created to investigate the effect generated by the curvature for the residual stress after bonding. Curvature function was exploited to describe the non-planar surface wavy condition derived from optimized impacting angle for achieving bonding phenomenon. This numerical simulation work can provide further insights for the residual stress evolution status in the condition of realized cohesion between impactor and non-planar surface after a kinetic peening process. Beneficial suggestions toward cold spray technology utilization in additive manufacturing areas are concluded from the results of the numerical simulation.


First Advisor

Ian R. Grosse

Second Advisor

Robert W. Hyers

Third Advisor

Davoud Mashhadijafarlou

Creative Commons License

Creative Commons Attribution-Noncommercial 4.0 License
This work is licensed under a Creative Commons Attribution-Noncommercial 4.0 License