This new article series explores the indispensable role of characterization in the development of cold spray coatings and illustrates some of the common processes used during coatings development. This article provides a list of techniques to be covered in subsequent articles.

This article series explores the indispensable role of characterization in the development of cold spray coatings. X-ray diffraction (XRD) is a versatile tool for preliminary characterization of phases in cold spray coatings. Research studies have made use of XRD to characterize powders and as-sprayed coatings, to determine the extent of lattice strain, to identify phase transformations in as-sprayed versus heat treated conditions, and to measure grain size.

This article series explores the indispensable role of characterization in the development of cold spray coatings. Transmission electron microscopy is used to understand powder characteristics, cold spray coating deformation behavior both within splats as well as near the coating-substrate interface, phase transformations in the as-sprayed and heat treated conditions, phase equilibria of the coating under the operating conditions pertaining to the application of the coating, the coating recovery mechanism, and the thermal stability of the coating.

This article series explores the indispensable role of characterization in the development of cold spray coatings. Electron backscatter diffraction (EBSD) is a characterization technique that enables determination of crystal orientations, texture, boundary misorientations and deformation behavior, and bonding mechanism in cold spray coatings.

Focused ion beam (FIB) systems are selectively used in cold spray coating characterization to gather information on the nature of splat formation, single splats, multiple splats, or the coating-substrate interface. Electron probe microanalysis has been used in cold-sprayed coating characterization primarily to understand the bonding mechanism at the coating-substrate interface.

This article series explores the indispensable role of characterization in the development of cold spray coatings and illustrates some of the common processes used during coating development.

This article series explores the indispensable role of characterization in the development of cold spray coatings and illustrates some of the common processes used during coating development.

This article series explores the indispensable role of characterization in the development of cold spray coatings and illustrates some of the common processes used during coating development.

Enhanced antiviral performance is associated with antipathogenic copper material consolidations obtained using cold spray processing.

Optical or light microscopy uses the visible or near-visible portion of the electromagnetic spectrum and is one of the oldest characterization techniques. With any cold spray coating, it is the first characterization process used to evaluate and optimize process variables.

This article series explores the indispensable role of characterization in the development of cold spray coatings and illustrates some of the common processes used during coating development.

In cold spray characterization, scanning electron microscopy is used to analyze feedstock powders for particle size, distribution, shape, and chemical composition prior to spraying. SEM is used extensively to characterize coating chemistry via energy-dispersive x-ray spectroscopy (EDS). Coating thickness and interface contour can be characterized in a manner that makes SEM an indispensable and versatile tool for evaluating coating integrity in the as-sprayed condition, as well as in developing an understanding of bonding to the substrate.

A joint Canadian project aims to curb the COVID-19 pandemic and future epidemics with cold sprayed, copper-based coatings. The objectives are: (1) to tailor the microstructure and surface state of Cu/Cu alloy cold spray coatings to maximize the antiviral activity and provide an economically viable solution that can be rapidly upscaled and industrialized; (2) to identify the most relevant high-touch surface components based on a systematic data-driven analysis and simulation of public infrastructure usage; and (3) to demonstrate viable production capability with real component demonstrators to be installed in public transport facilities for in situ testing.

Cold spray is uniquely suitable for depositing a wide range of materials over temperature-sensitive substrates. This article is a case study in using cold spray coatings to restore a 1937 Alfa Romeo 8C 2900B racing car.

Increasing and controlling particle impact temperature is proving to be beneficial for both process performance and coating properties.

Coating development using cold gas spray technology demonstrates the feasibility of bonding polymers to metal substrates and metals to polymer composite substrates with good adhesion. The examples addressed are polyetheretherketone (PEEK) coatings on steel and aluminum substrates and metallic coatings on carbon fiber reinforced polymer (CFRP) composites.

Cold spraying is a potentially attractive method for producing accident tolerant fuel cladding, near-net shape nuclear reactor components, and nuclear fuel storage canisters.

New thermal and cold spray technologies are being developed to extend the lifespan of thermal barrier coating (TBC) systems at elevated temperatures. This article describes the relevant attributes of coating technologies such as high velocity air fuel, high velocity air plasma spray, and high pressure cold spray for use in TBC systems.

A joint Canadian venture launches a new facility with an innovative hybrid approach to cold spray additive manufacturing. The technology platform combines multiple manufacturing steps in a single cold spray additive manufacturing (CSAM) unit, incorporating surface preparation, cold spray forming and buildup, local laser-based thermal treatment, and in-situ sequential robotic machining and semi-finishing.

The use of coatings to enhance the performance of components is one of the most powerful tools in materials engineering. This article highlights some examples of how thermal spray technologies are used to enhance surface properties for selected applications and industries.