Fatigue Properties and Crack Behavior of Cold Spray Coatings

Impact Deposition Behavior of Al/B4C Cold-Sprayed Composite Coatings: Understanding the Role of Porosity on Particle Retention

“…Among these techniques, the cold spray method [ 19 ] was recently adopted because of its favorable attributes: (1) the low temperature of the process ensures no phase change in the material [ 19 ], (2) materials with different thermal properties (e.g., ceramics and metals with very different melting points) and morphology can be mixed in the feedstock during the deposition process towards fabricating composite coatings [ 19 ], (3) cold spraying does not produce oxidation in the deposited coating [ 20 ], and (4) this technique generates lower residual stresses in the final coating when compared to other thermal spray techniques [ 21 ]. These features make the cold spray method a unique technique to manufacture composite coatings in order to reduce material consumption and tailor the physical, mechanical, and tribological properties by blending dissimilar materials to provide commercial products for a variety of industrial applications including [ 21 ] to repair magnesium parts in aerospace [ 22 ], manufacture electro- or thermo-conductive coatings for power electronic circuit boards [ 23 ], design of orthopedic devices [ 22 ] in biomedical implants [ 24 ]. Moreover, cold-sprayed composite coatings are highly appealing because they do not undergo alloying, phase transformation, or thermite reactions during fabrication processes [ 25 ].…”

Recent advances on bonding mechanism in cold spray process: A review of single-particle impact methods

“…Cold spray (CS) process is a solid-state deposition process in which microparticles are accelerated to supersonic velocities by pressured gas; these particles adhere to an oppositely positioned substrate and/or previously deposited particles to develop coatings/parts [ 1 , 2 ]. CS is a member of the thermal coating techniques such as the high-velocity oxygen-fuel, flame spraying, and plasma spraying.…”

“…Powder feed rate between 10 and 30 g/s should be carefully selected for improved CS deposit quality [ 13 , 14 ]. Nozzle parameters : The most important nozzle parameters include nozzle transverse speed, stand-off-distance (SoD)—the gap between the spray nozzle and the substrate, and spray angle—the angle between the nozzle central axis and the substrate [ 2 ]. The nozzle transverse speed affects the duration and quantity of powder impinging the substrate per unit time.…”

“… Varying deposition rates resulting from nozzle obturation during prolonged spraying processes; this reduces coating quality [ 43 ]. Difficulty in coating/processing substrates with the large surface area due to small spray path/trace and short stand-off-distance [ 2 ]. …”

“…Difficulty in coating/processing substrates with the large surface area due to small spray path/trace and short stand-off-distance [ 2 ].…”