Mechanically mixed Al-Ni powders with different nickel fractions were deposited on Cu substrates by kinetic spraying. Deposition efficiency and porosity were measured and finite element analysis was used to model single and multiple particle impacts. Increasing the fraction of nickel in the feedstock powder reduced the porosity of the Al-Ni coatings but at the expense of deposition efficiency. The reason for this is explained based on particle velocity measurements and impact models. With that information, dense, well adhered coatings were produced by increasing the tamping effect of Ni, resulting in local melting of the Al at the Al-Ni interface.

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