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Ti2AlC coatings have been fabricated by cold-spray deposition. The microstructure evolution as a function of basic spray parameters temperature and pressure onto AA6060 aluminium alloy and 1.0037 steel substrates has been studied. Adherent and dense 50–80 μm thick Ti2AlC coatings were deposited on soft AA6060 substrates under gas temperature and pressure of 600 °C and 3.4 MPa, respectively, whilst comparable results were obtained on harder 1.0037 steel by using higher temperature (800 °C) and pressure (3.9 MPa)

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he deposition of pore free and highly adhered Ni and Co superalloy coatings is of great interest for engine design and gas turbine applications, both in oase of maintenance repair and overhaul operations as well for mechanical and chemical protection purposes in aeronautics and energy applications. This study would like to give a wide overview about the capability of cold spray technology on this topic: two different commercially available deposition systems, Sulzer-CGT Kinetiks 4000 and Plasma Giken PCS-1000, were compared, and deposition processes with both nitrogen and helium as carrier gas have been explored. Microstructural investigation, microhardness and adhesion results are reported to depict a preliminary scenario of coating properties. Fully dense coatings with thickness >1 mm and adhesion >50 MPa are obtained using helium, while quite porous, 20 MPa adhered coatings are obtained using nitrogen. Finally, general considerations about the potential applicability of those coatings for repair purpose in aerospace applications are pointed out.

Cold spray is a solid state spray deposition process utilizing a supersonic De Laval nozzle to accelerate fine particles to high velocities. Particles plastically deform on impact to the substrate and to each other to create dense well adhered structures. In this study, the microstructure and mechanical properties of cold spray Titanium coatings deposited using nitrogen gas at different gas temperature and pressure were examined. In general, it was found that gas-atomised CP-titanium powder is capable of producing dense coating structures on aluminium alloy (Al6061) substrates. The micro-hardness, oxygen and nitrogen content of the coatings were found to be slightly higher than powder in the as-received condition. It was also found the coating residual stress was purely compressive when cold spray is conducted at high gas pressure and temperature.

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