Numerical analysis of particle impacting and bonding processes during high velocity oxygen fuel spraying process

•The dynamic impact behavior of the particle and substrate is investigated.•The effect of particle velocity on the impacting process is analyzed.•The effect of particle temperature on the impacting process is analyzed.•The effect of different substrate material on the impacting process is analyzed. In this paper, the dynamic impact behavior of a particle and a substrate under different particle temperatures and velocities as well as using different materials for the particle and substrate were systematically studied. We found that the highest temperature occurred at the side edge of the particle after the collision, which is consistent with the distribution of equivalent plastic strain. The deformation of the particle and substrate was very severe at the first 40ns, slowed down after 40ns and remained almost unchanged after 80ns. With the increase in the particle velocity, the effective combination area became larger, the equivalent plastic strain of the substrate is increased, and the equivalent plastic strain of the particle is decreased. As the initial temperature of particles increased, the effective combination area between the particle and substrate increased, and higher temperature and larger equivalent plastic strain of the particle could be obtained. With the increase in the substrate strength, the temperature and the equivalent plastic strain of the particle is increased, whereas the plastic deformation of the substrate is decreased.