Abstract
This study investigates the impact behavior and consequences for coating formation in cold spraying of FeAl intermetallic compound powder. A range of spraying conditions was used to process single impacts in so-called wipe tests and for processing spray layers. In order to avoid brittle failure, high process gas temperatures and varied traverse speeds were used to account for thermal softening of spray particles and already adhering layers. Morphologies of as-impacted particles and partially removed single splats were subsequently investigated by SEM. The study of spray lines indicates that secondary impacts are only successful within an extremely narrow range of impact conditions. Within this narrow parameter regime, thicker and dense coatings are obtained. Hardness testing shows that the properties of the powders were retained.
