Date Approved

6-30-2025

Embargo Period

6-30-2025

Document Type

Thesis

Degree Name

M.S. Mechanical Engineering

Department

Mechanical Engineering

College

Henry M. Rowan College of Engineering

Advisor

Joseph Stanzione, III, Ph.D.

Committee Member 1

Francis M. Haas, Ph.D.

Committee Member 2

Behrad Koohbor, Ph.D.

Keywords

cold spray;high-speed videography;high-strain rate;impact characterization

Disciplines

Engineering | Mechanical Engineering

Abstract

The primary objective of this research is to provide insight into high strain rate deformation behavior of particles in cold spray-like impacts for the purposes of material vetting and optimization of spray parameters for deposition quality and efficiency. A light gas gun and ultra-high-speed videography techniques were engineered, built, and used for millimeter particle impact experiments and adapted to launch micron scale particles at controlled velocities and particle/substrate temperatures representative of cold spray conditions. Analytical techniques employed for understanding impact mechanics focused on characterization of impact behavior and presence of features related to cold spray particle bonding. This research demonstrates the capabilities of a new in situ experimental approach in capturing real-time deformation characteristics and viscoelastic behaviors of particles during high strain-rate impacts that are not apparent through traditional stroboscopic imaging or ex-situ characterization methods. Observing these high strain-rate deformations with the developed techniques furthers understanding of cold spray adhesion and deposition mechanisms with control over spray conditions beyond alternative impact experimentation techniques. This results in actionable insights for improving material selection, process parameters, and deposition strategies across a wide range of cold spray applications while expanding on capabilities of cold spray characterization methods.

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