Quantitative prediction of critical velocity and deposition efficiency in cold-spray: A finite-element study

[Display omitted] Using finite element simulations, we examined the impact deformation of three different particle/substrate systems during cold-spray. A new approach based on the equivalent plastic strain averaged over the impact particle (PEEQ‾2) was employed to analyze the deformation and a rate parameter REQ, the steady rate of change of PEEQ‾2, was introduced. An excellent correlation between this rate parameter and experimental deposition efficiency is obtained. For the first time, a quantitative prediction of the deposition efficiency for cold-spray has been generated.