Metal particle acceleration to supersonic speed: Numerical simulation and preliminary results

Cold spray, because of its solid-state deposition nature retains the original properties of the feedstock to produce oxide-free deposits and not adversely affect underlying substrate material during manufacturing while maintaining high deposition rate. However, deposition accuracy, high operational cost for high velocity requirements, are some of the few limitations that are yet to be addressed. This work explores a novel solid-state deposition principle using a linear accelerator (LINAC) system, inspired by the cold spray process where material deposition and bonding occur through high plastic deformation. The purpose of this study is to validate the concept using numerical simulation model. It includes assessing the influence of applied electric field on charged particle using high voltage cylindrical accelerators. Influence of different parameters on final particle velocity like applied voltage V, number of accelerators N and charge-to-mass ratio q/m are analyzed by simulating model for three different parameter conditions and compared with the formulation. Compared to the conventional cold spray process, this proposed method offers better control over particle velocity and deposition accuracy through electric field modulation, improving resolution for intricate structures.