The smoothed particle hydrodynamics (SPH) method is applied to simulate the cold spray (CS) process by modeling the impact of a spherical powder particle on substrate. In this work, the adhesive interaction between the contacting surfaces is described by intersurface forces using the cohesive zone model. The application of the SPH method permits simulation of the impact process without the use of mesh and thus avoids the disadvantages of traditional numerical method in handling large deformations and tracing moving interfaces in the highly transient non-linear dynamic CS process. The simulated deformed particle shape evolution and estimated critical velocity from other sources were compared and good agreement was obtained. The analyses demonstrate the feasibility of the presented SPH methodology and the adhesive interaction model for simulating the deformation behavior of CS particles.
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