Thermal-sprayed (i.e. LPPS or HVOF) MCrAlY coatings are widely used for land-based gas turbine applications against high-temperature oxidation and hot corrosion. However, due to requirement for further improvement of turbine efficiency, dense and stable coatings are necessary. The cold spray (also referred to as cold gas dynamic spray) makes it possible to increase coating density, due to high velocity particle impact during spraying. However, deposition mechanisms of cold spraying have not been elucidated yet. In this study, we investigated the deposition mechanisms focused on the behavior of interface between a coating and a substrate. The mechanisms were evaluated by the spray impact phenomena simulation tests, namely laser shock flier impact tests, and STEM-EDX elemental analyses at the interface between the substrate and the cold sprayed coating. From the results of STEM-EDX for as-sprayed coating and of SEM-EDX of the flier specimen, the bonding between the CoNiCrAlY coating and the substrate occurred at the only particular phase combination.

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