Nozzle fouling in cold spray: Material transfer between Ni particles and WC-Co substrates at shallow impact angles and elevated surface temperatures

Experimental and theoretical investigations of nozzle clogging in WC-Co cold spray nozzles using nickel powder were conducted. Computational fluid dynamics (CFD) was used to show that the highest particle impact kinetic energy density occurs just downstream of the nozzle throat, where clogging is common. CFD also showed particles impact the nozzle wall at angles between 0.3°–5°, with smaller particles having higher velocities and temperatures. An experimental setup was used to investigate the effects of substrate temperature, surface roughness, and incidence angles on material deposition. Scanning electron microscopy revealed nickel particles smeared on the substrate surface, with more deposition on smoother surfaces. Energy dispersive X-ray spectroscopy (EDS) showed more nickel deposited at higher substrate temperatures and lower impact angles. Finite element simulations indicated nickel powder reaches temperatures above its melting point while sliding along the WC-Co substrate and predicted localized melting. Particle smearing is identified as the cause of nozzle clogging based on experimental and simulation results. •Oblique particle impacts cause clogging in cold spray nozzles.•Impacts 40–100 mm after the nozzle throat, at 0.3°–5° deposit on the surface.•Deposition increases at higher substrate temperatures and shallower impact angles.•Nickel powder interface melts while sliding along the substrate due to friction.•Stacked nickel layers, each 10–30 nm thick, are observed on the substrate.