The prediction of material behavior and its microstructural evolution during high velocity impacts has been investigated for decades. The application of this topic can be observed in various engineering applications such as the cold spray process. Cold spray (CS) is an additive manufacturing method in which solid particles are accelerated using a low temperature supersonic inert gas flow, prior to their impact onto a substrate and adhesion/consolidation. In this process, unlike other thermal spray processes, the particles are kept well below their melting point prior to impact. This allows the CS process to be used for the manufacturing of high quality, specialized products at a low energy input. In CS, the deformation and bonding processes happen in a very short time (less than 100 ns). With the current technology, in-situ investigation is almost impossible. In this situation, numerical modeling methods are the best alternative to study the deposition process. There are several factors influencing the particle deposition, such as particle/substrate material properties, particle size, material temperature, particle velocity and so on, but it has been shown that the particle impact velocity has the major role during the deposition process. In fact, despite the type of bonding, i.e., mechanical or chemical, particle is sticking to the substrate after experiencing severe plastic deformation that occurs upon the impact at high velocities. Therefore, in order to develop the understating of the CS process, investigating the deformation behavior of material during high velocity impacts, and also bonding mechanisms involved during particle deposition must be investigated. III Although numerous studies have been done to explore the mechanisms occurring during particle deposition, the details of this process are still unclear. Therefore, the purpose of this research is to study the fundamental aspects of material behavior during the deformation and deposition processes with the aim of improving the understating of the CS process. Two different numerical approaches will be used to achieve the objective of the study, i.e., Finite Element Method (FEM) and Molecular Dynamics (MD) method. FEM will be used to study the metallic bonding occurring between the particle and the substrate. A physically based model to predict this phenomenon will be implemented into ABAQUS/Explicit FEM software. MD simulations will be performed to investigate the microstructure evolution during high velocity impacts. In order to characterize the deformation behavior of materials at a fundamental level, analysis will be focused on the basic mechanisms of plasticity and hardening in metals, i.e., the multiplication, glide and locking of dislocations, and also solid-state amorphization that happens at high strain rate deformations.

La projection à froid, aussi appelée cold spray, est considérée comme un nouveau membre de la famille de laprojection thermique depuis une trentaine d'années maintenant. Cette thèse propose d'étudier le comportement endéformation des particules et du substrat et de mettre en avant les liaisons formées dans le revêtement par deuxapproches complémentaires, expérimentale et de simulation.Une méthode innovante pour observer directement la surface fracturée des particules déposées après décollementdu substrat a été testée avec succès. Par ce moyen, la surface de contact entre particule et substrat sousdifférentes conditions a été analysée.Concernant les résultats expérimentaux, une nouvelle théorie a été proposée pour expliquer le mécanisme deliaison interfaciale d'un revêtement dur de Ni sur substrat mou d'Al reposant sur l'effet de martelage répété desparticules, sur l'effet de pression du gaz principal et sur l'effet de préchauffage du substrat. La transformation dumécanisme de liaison revêtement/substrat au cours de la construction du dépôt a été mise en évidence en passantdu verrouillage mécanique à une combinaison d'une liaison mécanique et d'une liaison métallurgique, puis à laformation d'instabilités sous forme d'un mélange tourbillonnaire à l'interface. Plus de zones de liaisonsmétallurgiques sont générées sous forte pression, une plus grande déformation plastique apparaît grâce latempérature de préchauffage, et une adhérence plus forte au sein des dépôts est capable de se produire en dépitde la présence d'un film d'oxyde épais sur la surface du substrat. / Cold spraying, also called cold gas dynamic spraying, is a new coating technology which has been developed duringthe past three decade. In this study, a comprehensive investigation on particle deformation behavior and bondingbehavior between particle and substrate was conducted by experiment and numerical method.This thesis aims at presenting an innovative method to directly observe the fractured contact surface between thecold sprayed particle and substrate. By this means, the particle/substrate fractured contact surfaces were analyzedfor different conditions.Based on the experimental results, a new theory was proposed to explain the interfacial bonding mechanism of hardNi coating onto soft Al substrate. It is assumed that the particle peening effect is essential for the formation ofdiscontinuous metallurgical bonding. The dominant coating/substrate bonding mechanism is responsible of thetransformation during the coating build-up process of the initial mechanical interlocking to a combination ofmechanical interlocking and metallurgical bonding therefore of the formation of interfacial instabilities. The highcontact pressure is the relevant factor determining the particle/substrate metallurgical bonding. More metallurgicalbonding areas were generated due to strengthen peening effect of the subsequently deposited particles with higherpropelling gas pressure. Finally, stronger adhesion is able to occur despite the presence of a thick oxide film on thesubstrate surface by the preheating of the substrate. Higher temperatures help the materials to undergoes astronger plastic deformation that disrupts the oxide films. That leads to initiate an intimate contact between particleand substrate.

The objective of this study is to successfully deposit Titanium Ti-6Al-4V layers onto Ti-6Al-4V substrate using two new commercially available Cold Spray processes such as Low Pressure Cold Spray (LPCS) and Pulsed Gas Dynamic Spray (PGDS). The second objective of this work is to develop a technique to repair Titanium parts since there is currently no repair technique commercially available. It is envisioned that commercial cold spray systems could be used to repair gashes on Titanium components. The examination of both feedstock powders and coatings were performed by different techniques such as optical microscopy and Scanning Electron Microscopy (SEM). Porosity, hardness, adhesion strength, flattening ratio, wipe test, fracture surface, wear test, XRD and chemical composition of the coatings using EDS have been evaluated. Cold spray has shown to be a promising technique for the deposition of heat sensitive particles such as titanium. LPCS and PGDS both produced high quality coatings. Low porosity, high hardness, adhesion strength over 40 MPa, metallurgical bonding, similar to bulk material wear rate, no oxide and nitride phases inside coating were measured.