This study investigates the in-flight behavior of particles during cold spraying by means of high-speed shadowgraph photography using a laser imaging system. It also characterizes the particle jet outside the nozzle for different powder sizes (<10 µm to 155 µm) and densities (copper, aluminum). Observations of the jet reveal two low-pressure cold spray flow regimes, one stable, the other unstable, the effect and control of which are discussed.

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