The cold spray, for its peculiarity, is becoming increasingly in the reconstruction or repair of damage aluminium alloy components, especially in the aviation industry. Both thin (<0.5mm) and thick (up to centimeters) coatings are necessary in order to achieve dimensional recovery of the components. Contrary to thin, thick coatings can be deposited in single-pass or in multi-pass giving different thermal and stress contribution to the components and coatings itself. The thermal input, the amount and the type of residual stresses (compressive or tensile) confer appreciable or depreciable characteristics to the coatings adhesion, the crack propagation and the coating mechanical property. In this study two sets, single and multi-pass aluminium alloy coatings of different thickness are deposited into Al6061 substrate. The metallographic analysis by electronic and optical microscopes, the four-point bending test and the Vickers microhardness are performed; also the multi-pass coatings were characterized by fractographic analysis. Finally the different coating adhesions to substrate and cohesions are compared by standard ASTM C633 adhesion and cohesion tests.