The impact of binding energies on the necessary conditions in aerosol deposition

Abstract Aerosol deposition (AD) enables the formation of dense ceramic coatings by high velocity impact of submicron‐sized particles. However, up to now, it is still not clear how the material properties of the ceramic powder particles influence their impact behavior and possible success in layer build‐up in AD. Therefore, in order to provide a broader understanding, this study utilizes molecular dynamic (MD) simulations to investigate the impacts of single‐crystalline particles while manipulating binding energies, particle sizes, and impact velocities, addressing a rather wide range of different materials and process conditions. The findings reveal that increasing binding energies from 0.22 to 0.96 eV necessitates up to three times higher velocities to reach thresholds for bonding and fragmentation, which are linked to potential layer formation. For conditions above the velocity thresholds given by individual binding energies, similarities in the deformation and fragmentation patterns are derived. Consequently, rough estimations regarding the required particle impact velocities for AD of different materials can be inferred.