Document Type

Thesis - Open Access

Award Date


Degree Name

Master of Science (MS)

Department / School

Mechanical Engineering

First Advisor

Jeffrey Doom


CFD, Cold Spray, Simulations


Computational Fluid Dynamics (CFD) is a useful tool when it comes to research in the fields of Aerodynamics, Turbomachinery, and is used in several other fields of research. CFD is an important tool in the engineering industry because it allows for understanding and evaluation of a new design, this can lead to advancements in developing a more efficient and effective design. This tool helps in the understanding of the flow phenomena and how it can interact with its surroundings. One of the main reasons in the use of CFD is to reduce the cost of testing a design by running simulations, whereas creating an experimental apparatus to test a design would lead to a higher cost. A CFD analysis can be done on coating technologies to evaluate their performance and behavior. Coating technology has a wide variety of applications such as: oxidation protection, corrosion protection, aid in repairs, and thermal protection. One of the most researched coating technologies is Cold Spray Technology, this technology is relatively new and has many unique characteristics. Cold spray is used to manufacture coatings in the solid state, fully preserving the feedstock material properties. This coating is done by the compression of the carrier gas in a converging section of the nozzle, followed by a diverging section where the thermal energy is converted into kinetic energy, thereby speeding up the particles to their desired velocity and creates a non-thermal coating on the substrate. This thesis is focused on the proper procedure that must be taken to create and run a simulation on the injection of particles into a cold spray nozzle. This procedure is broken down into the study of physics models, the desired mesh that must be analyzed and evaluated to obtain adequate simulations and results. These simulations will be able to demonstrate the behavior of the particles as they travel through the cold spray nozzle, thus being able to compare different carrier gases and evaluate which would perform better with the particles. The studies performed were done by using different meshing densities using the k- Omega turbulent models provided in StarCCM+ solver. Validation is very important to ensure that the results are adequate. The validation step was done by comparing the simulations ran to the simulations done by Muhammad Faizan Ur Rab. By comparing the simulations we are able to validate the studies.

Library of Congress Subject Headings

Coating processes.
Computational fluid dynamics.
Cold gases.



Number of Pages



South Dakota State University



Rights Statement

In Copyright