Cold gas dynamic spray is being explored as a repair technique for high-value metallic components, given its potential to produce pore and oxide-free deposits of between several micrometers and several millimeters thick with good levels of adhesion and mechanical strength. However, feedstock powders for cold spray experience rapid solidification if manufactured by gas atomization and hence can exhibit non-equilibrium microstructures and localized segregation of alloying elements. Here, we used sealed quartz tube solution heat treatment of a precipitation hardenable 7075 aluminum alloy feedstock to yield a consistent and homogeneous powder phase composition and microstructure prior to cold spraying, aiming for a more controllable heat treatment response of the cold spray deposits. It was shown that the dendritic microstructure and solute segregation in the gas-atomized powders were altered, such that the heat-treated powder exhibits a homogeneous distribution of solute atoms. Micro-indentation testing revealed that the heat-treated powder exhibited a mean hardness decrease of nearly 25% compared to the as-received powder. Deformation of the powder particles was enhanced by heat treatment, resulting in an improved coating with higher thickness (* 300 lm compared to * 40 lm for untreated feedstock). Improved particlesubstrate bonding was evidenced by formation of jets at the particle boundaries.

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SPS titania coatings, with applications in water purification, were formed using continuous hydrothermally produced feedstocks for the first time. Coating photoactivity was compared with CVD and P25 analogues.

The deposition parameters of WC-17%Co coatings produced using the JP-5000 liquid-fuel HP/HVOF system (Eutectic TAFA) were investigated with the initial purpose of parameter improvement and optimization. The coating microstructures, porosities, phase compositions, and abrasion resistance were characterized. Preliminary work using the Taguchi statistical experimental design method aimed at optimizing the spray parameters in terms of the microstructure and phase composition was unsuccessful. The variations in the measured properties were too small to be correlated with the spray parameters. Subsequent experiments showed this was primarily due to the fact that the properties, particularly the abrasion resistance, of the WC-Co coatings were not primarily influenced by variations in the spray parameters, but were more dependent on the powder composition, particle size range, and manufacturing route. Hence, the application of Taguchi techniques would have been more effective over a much wider parameter space than was originally used. This result is valuable because it suggests that this process is robust and can be used for WC-Co coatings without large investments in spray parameter optimization and control once the coating and powder type have been fixed. 3HHU 5HYLHZHG