Design of the Dual-Path Cold Spray Nozzle to Improve Deposition Efficiency

This paper designs a Dual path cold spray nozzle and studies its performance during the cold spray process through numerical simulations and optimization experiments. The gas flow field inside the nozzle and the particle acceleration process were simulated using Fluent software2020R1. The orthogonal experimental method was used to analyze the effects of five geometric parameters on the nozzle performance, determining the optimal design parameter combination. Modeling and simulation calculations based on the optimal parameter combination showed that the average particle impact velocity increased by nearly 17 m/s, the number of particles exceeding the theoretical critical velocity increased by nearly 100, and the theoretical deposition efficiency improved by 10%. Experimental results indicated that compared to the single-channel nozzle, the deposition efficiency increased from 20.22% to 28.26%, the porosity improved from 10.51% to 9.12%, and the deposition microhardness also increased. The experimental test data were in good agreement with the previous numerical simulation results, validating the accuracy of the simulation model and providing an important theoretical reference for the optimization and improvement of subsequent process parameters.