Application and assessment of the improved delayed detached eddy simulation model to the cold spray process: Toward high fidelity computation fluid dynamics simulations

Abstract

Despite many years of research about the comprehension of fluid-dynamic related phenomena and improvements in the performance of cold spray systems, ensuring high fidelity simulations of gas and particle flow remains a challenge. In this work, a detailed high fidelity modeling, namely, improved delayed detached eddy simulation, in axisymmetric geometries was proposed and compared with a more usual numerical framework, the Reynolds averaged Navier–Stokes model. After its validation against literature data in three different nozzle configurations, the new model could demonstrate more accurate predictions of phenomena such as oblique shocks, bow shock, and particle–gas flow coupling. Finally, thanks to the high fidelity numerical framework, a new nozzle geometry with a narrower extension of the particle jet was proposed and assessed.