Fundamental Cost Analysis of Cold Spray

This report analyzes the cost structure of the cold spray process using a generic model applicable to various systems (high pressure, low pressure, kinetic) and applications (coating, restoration, additive manufacturing, near-net forming). The cost model is relatively easy to use, yet sufficiently accurate to support decisions. It is shown that high-pressure spraying is generally favorable, that He-N2 gas blends are the most economic, and that He recovery is beneficial in high-volume production, even when He-N2 blends are used. The cost model makes it possible to determine the optimal He concentration of the propellant gas for a given application as demonstrated in a case study involving bond coats for gas turbine blades.