An analysis of physical and mechanical properties of coatings produced by kinetic and cold spray processes is presented. Adhesion, hardnesses, porosities, critical velocities and other properties of aluminum and copper coatings from both spray methods will be analyzed and discussed, including SEM and optical micrographs. Similarities and differences between each of the coating methods and their effects on the resulting coatings are presented. A brief history and discussion of the bonding mechanisms for larger particle coatings produced by the kinetic spray method is provided.

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