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Geometric confinement in cold spray: a molecular dynamics study of particle anchoring mechanisms
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DOI：10.1007/s40964-026-01907-1.png)
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Abstract
En 中文
Cold spray deposition relies on high-velocity particle impact, where adhesion is governed by particle deformation, stress evolution, and substrate geometry. While most molecular dynamics (MD) studies have focused on flat substrates, the influence of engineered surface confinement on particle anchoring remains poorly understood. In this work, MD simulations were performed to investigate the combined effects of substrate cavity geometry, defined by cavity opening angle (θ = 60°, 90°, and 120°) and cavity depth (d = 1–3 nm), together with particle impact velocity (250–1000 m s⁻¹), on particle anchoring behaviour. Particle deformation was characterised using two dimensionless geometric descriptors, namely the particle diameter-to-cavity opening ratio (DtO) and particle diameter-to-cavity depth ratio (Dtd), together with hydrostatic stress, von Mises stress, and particle retention within the cavity. The results show that Dtd establishes the overall level of geometric confinement, whereas variation in DtO differentiates material redistribution within each confinement level. Increasing particle velocity increases the magnitude of hydrostatic and von Mises stresses but does not alter the confinement group defined by cavity geometry. Comparison with experimental observations demonstrates that effective anchoring is governed not by cavity filling alone, but by the coupled effects of particle retention, hydrostatic confinement, and plastic accommodation. The proposed DtO–Dtd descriptor framework establishes a quantitative geometry–stress–deformation relationship that provides practical guidance for the design of textured substrates to enhance particle anchoring in cold spray additive manufacturing.
Keywords:
Cold spray
Additive manufacturing
Particle anchoring
Geometric confinement
Surface engineering
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