Economic Potential of Cold Spraying MCrAlY Coatings: Use of Nitrogen and Feasibility of Powder Recycling Available to Purchase

In this study, nitrogen is employed rather than helium to cold spray MCrAlY coatings at relatively low process settings. Recycling of the non-deposited particles during the spray is also explored, and the characteristics and cold sprayability of recycled powder are compared with that of as-received feedstock powder. The resulting MCrAlY coatings from the two powders, though different thicknesses, show similar dense microstructures, low oxide inclusion, and smooth surface finish, all of which contribute to improved oxidation behavior.