颗粒形状影响冷喷涂喷流特性，决定涂层质量。
Influence of the particle morphology on the spray characteristics in low-pressure cold gas process
- 用2D/3D成像分析铜粉形状差异。
- 不规则颗粒加速快、喷流集中，球形颗粒速度低、分散广。
- 为增材制造优化提供关键参数依据。
本研究通过分析三种不同形貌和微观结构的铜粉，探究颗粒形貌对低压冷气体喷涂（LPCGS）喷流特性的影响。采用二维和三维成像技术进行综合形貌分析：光学显微镜结合图像处理量化了颗粒在二维投影中的圆度；同步辐射微焦点计算机断层扫描（micro-CT）实现了精确的三维重构，用于测定球度、比表面积及体积分布。结果表明，所研究的进料铜粉形貌差异显著，不规则颗粒的圆度与球度明显低于球形颗粒。这些形貌差异直接影响粒子速度分布与喷流空间分散性，高帧率粒子图像测速（high-speed PIV）测量显示，不规则颗粒经历更强加速，喷流更集中；而球形颗粒最大速度较低，喷流分散更广。研究揭示了颗粒形貌在先进涂层与增材制造冷喷涂工艺优化中的关键作用。
原文摘要 · Abstract (English)
This study investigates the influence of particle morphology on spray characteristics in low-pressure cold gas spraying (LPCGS) by analyzing three copper powders with distinct shapes and microstructures. A comprehensive morphology analysis was conducted using both 2D and 3D imaging techniques. Light microscopy combined with image processing quantified particle circularity in 2D projections, while X-ray micro-computed tomography (micro-CT) enabled precise 3D reconstructions to determine sphericity, surface area, and volume distributions. The results showed significant variations in the particle morphology of the investigated feedstock copper powders, with irregularly shaped particles exhibiting lower circularity and sphericity compared to more spherical feedstocks. These morphological differences had a direct impact on the particle velocity distributions and spatial dispersion within the spray jet, as measured by high-speed particle image velocimetry. Irregular particles experienced stronger acceleration and exhibited a more focused spray dispersion, whereas spherical particles reached lower maximum velocities and showed a wider dispersion in the jet. These findings highlight the critical role of particle morphology in optimization of cold spray processes for advanced coating and additive manufacturing applications.
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