This study deals with the influence of spray angle on the deposition of cold-sprayed Al particles. Spray trails were conducted in parallel with finite element simulations of particle deformation and coating build-up as a function of spray angle, powder size, substrate roughness, and surface configuration. Coating cross-sections and splats were examined by SEM; bonding strength and particle adhesion were determined via laser shock adhesion testing. Experimental as well as modeling results show that splats deposited at spray angles less than 60° are highly deformed and poorly adhered. Based on the findings, several conclusions are drawn with regard to the potential use of cold spraying for the repair of aircraft components.

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