High density and low porosity of gas dynamic sprayed coatings may provide gases and liquids impermeability. But jet deflection and stagnation in the narrow splits and reach-through holes prevent from sealing up the deep substrate defects by gas dynamic spray. The correct choice of powder blend makes the gas dynamic spray process applicable to the splits and holes sealing up. The approaches to the defects sealing up by gas dynamic spray and some applications are presented and discussed.

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