A new approach to simulate coating thickness in cold spray

Abstract In the process of cold spray on complex components, the coating thickness is an important indicator to monitor and control. Current methods such as destructive tests or direct mechanical measurements can only be performed after spraying. Besides, these methods lead to production shutdown and additional costs . This article presents a novel approach predicting coating thickness for components with complex curved surfaces, especially in the case of shadow effects. Firstly, a three-dimensional geometric model of the coating profile based on Gaussian distribution was developed. In addition, the relative deposition efficiency (RDE) resulting from the different robot kinematic parameters…