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<p>The present work characterizes the critical influence of particle mass loading on gas flow, 1-5-μm particle dynamic behavior, impact and deposition characteristics in micro-cold spray direct writing (MCSDW), which is a promising technique for microscale additive manufacturing. Through two-way coupled Eulerian–Lagrangian modeling, a critical threshold of particle loading is identified, which governs the transition from a uniform to nonuniform particle distribution. When the loading exceeds the threshold, the localized gas flow decelerates in the region of particle presence. The higher loading further reduces the particle impact velocity, widens the impact linewidth and decreases the deposition efficiency. A sensitivity analysis reveals that small particles and high inlet pressure further enhance the particle loading effects. To achieve a uniform coating with effective deposition in our cases considered, the particle loading should not be greater than the critical threshold (0.2%), the particle diameter should be ≤ 2&#xa0;μm, and the inlet pressure should be <InlineEquation ID="IEq1"> <EquationSource Format="TEX">\(\ge\)</EquationSource> <EquationSource Format="MATHML"><math> <mo>≥</mo> </math></EquationSource> </InlineEquation> 3.0&#xa0;MPa. These findings advance the understanding of the mechanism of MCSDW and provide actionable strategies for precision additive manufacturing of micro features and patterns.</p>

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Influence of Particle Loading in Micro-Cold Spray Direct Writing

  • 期刊论文

  • 发表日期：

    2026年3月23日

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  • Renjie Pan,
  • Juanfang Liu,
  • Zuying Shen,
  • Jun Song

摘要

The present work characterizes the critical influence of particle mass loading on gas flow, 1-5-μm particle dynamic behavior, impact and deposition characteristics in micro-cold spray direct writing (MCSDW), which is a promising technique for microscale additive manufacturing. Through two-way coupled Eulerian–Lagrangian modeling, a critical threshold of particle loading is identified, which governs the transition from a uniform to nonuniform particle distribution. When the loading exceeds the threshold, the localized gas flow decelerates in the region of particle presence. The higher loading further reduces the particle impact velocity, widens the impact linewidth and decreases the deposition efficiency. A sensitivity analysis reveals that small particles and high inlet pressure further enhance the particle loading effects. To achieve a uniform coating with effective deposition in our cases considered, the particle loading should not be greater than the critical threshold (0.2%), the particle diameter should be ≤ 2 μm, and the inlet pressure should be \(\ge\) ≥ 3.0 MPa. These findings advance the understanding of the mechanism of MCSDW and provide actionable strategies for precision additive manufacturing of micro features and patterns.