In this study, nickel and Inconel coatings were deposited on aluminum and steel substrates by cold gas spraying. Fine, standard, and coarse nickel powders and two standard Inconel (625 and 718) powders were selected as feedstock materials and sprayed at different gas pressures and temperatures. A coaxial air-cooled nozzle was used in spray trials, except for the fine Ni powder, which required a water-cooled nozzle to prevent clogging at high temperatures. Coating microstructures were examined and various properties were measured including shear strength, adhesive tensile strength, hardness, and porosity. Cross-sectional images of different coating samples are presented and discussed along with test results.

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