The cold spray coating properties and performances are largely affected by feedstock characteristics and the employed processing parameters. Starting from experimental results obtained from the bibliographic data, the relationships between starting particles, processing conditions, and coating properties obtained by cold gas spray were analyzed. The relationships among these properties and particle velocity were described for various material systems. The effect on particle flattening, hardness, and porosity were largely described. Finally, the influence of the different parameters on the process output and on the coating properties was analytically defined through the employment of the multi-objective simulation tool modeFRONTIER. The analysis of data from the bibliography is a new trend that can also be applied to cold spray in order to analyze the effect of powder properties and spraying parameters on the cold spray (CS) process.

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Metallic infrastructures suffer deterioration during their service life. When the metallic component reaches a limit level of damage, it is replaced by a new one. This generates high costs of maintenance and residues management. However, the deposition of coatings by the cold spray technique would allow the repairing of these damaged components and extent their service life. In this work the effect of the spraying temperature and pressure on the mechanical behavior of 316L stainless steel coatings deposited on carbon steel by the cold-spray technique has been analyzed. Spraying gas temperatures of 800oC, 900oC and 1000oC combined with gas pressures of 50 and 60 bars were selected. Indentation stress-strain curves were determined for each spraying conditions. The results showed a significant effect of both spraying parameters on the work hardening of the coatings.

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For decades, zinc- and aluminum-based coatings have been considered the best material choice for steel corrosion protection since they may act as a protective barrier and show sacrificial behavior. These coatings are often prepared by galvanizing methods. However, their application by thermal spraying techniques (wire arc spraying, WAS and flame spraying, FS) has been proved as a cost-effective solution for the preparation of long-term corrosion-resistant coatings. This review selectively collects the most relevant information about the application and performance of these two techniques on Zn and Al coatings for corrosion protection. The report summarizes separately the Zn and Al data from the effect of the spraying parameters on coating properties on the one hand, and the results shown in long-term studies carried out in relevant and real exposure conditions, on the other. Finally, this review includes a description and comparison of the most recent advances found out with the novel and emerging spray technique, cold gas spray, for the deposition of Zn and Al coatings for corrosion protection purposes. Nevertheless, the use of this technique has not reached the stage of wide industrial application yet and therefore its long-term performance is unknown, which suggests that there is still room for further development.